Posi - Stop Troubleshooting Guide: Position Tracking Systems

Position
Tracking
Systems

Posi-‐Stop Troubleshooting Guide

January 2014
Version 1.0.0

Table of Contents
1 Introduction ........................................................................................................................................... 4
2 Posi-‐Stop User Interface and Connection Locations .............................................................................. 5
3 Posi-‐Stop Circuit Board .......................................................................................................................... 6
4 Posi-‐Stop Stationary Test ....................................................................................................................... 7
5 Posi-‐Stop Does Not Power Up ............................................................................................................... 8
5.1 Check Incoming Power On Terminal Block ...................................................................................... 8
5.2 Check Battery Voltage ..................................................................................................................... 9
5.3 Check Continuity Of Fuse ................................................................................................................. 9
5.4 Check Voltage To Pin Of On/Off Switch ......................................................................................... 10
5.5 Check Voltage Located At TB Top Of Main Board Above Fuse ...................................................... 12
5.6 Check Voltage Readings On 7805 At Top Of Main Board .............................................................. 13
6 Posi-‐Stop Powers Up, LED Displays Do Not Function ........................................................................... 14
6.1 Check voltage on LED board .......................................................................................................... 14
6.2 Check The 7805 On The LED Board ................................................................................................ 15
6.3 Check 12 Volt TB Coming From Main Board .................................................................................. 15
7 Solenoid Does Not Function Correctly ................................................................................................. 16
7.1 Check Voltage To Solenoid ............................................................................................................ 16
7.2 Check Connection In Junction Box On Solenoid ............................................................................. 17
7.3 New Style Solenoid Valve Functional Test ..................................................................................... 18
8 Proximity Switch or Encoder Does Not Function Correctly ................................................................. 19
8.1 Check Continuity Of Encoder/Proximity Switch Cable ................................................................... 19
8.2 Proximity Switch Installation/Tests ............................................................................................... 20
8.2.1 Check Sensor Installation .......................................................................................................................... 20
8.2.2 Test Proximity Switch Sensors ................................................................................................................... 21
8.2.3 Test Proximity Switch Sensor LEDs ............................................................................................................ 22
8.2.4 Test Proximity Switch Circuit Board .......................................................................................................... 23
8.2.5 Test Proximity Switch Sensors Through Circuit Board ............................................................................... 25
8.3 Check Voltage at Encoder/Proximity Switch Input Terminal on Main Board ................................ 26
Version 1.0.0 POSI-‐STOP PLUS TROUBLESHOOTING GUIDE 3

1 Introduction
This Troubleshooting Guide covers the most common issues that prevent the proper function of
the system. This is a living document, and as new issues arise, better identification procedures or
better corrective actions are developed. This guide will be updated and available on our web page
www.posi-‐stop.com. Please ensure all personnel involved in operation, maintenance and
management of the rig operations read the warning below, in the Operations Manual and on
every Posi-‐Stop Console on the right panel. Prior to starting a shift or change in Operator the
attached Pre-‐Shift Checklist should be followed and if any of the checklist items does not pass this
Guide will have the most common issues and corrective actions to correct the problem and have
proper operation of the Posi-‐Stop System.
4 POSI-‐STOP PLUS TROUBLESHOOTING Version 1.0.0

GUIDE

2 Posi-‐Stop User Interface and Connection Locations

Figure 1 – Posi-‐Stop—Front View

Figure 2 – Posi-‐Stop—Bottom View

3 Posi-‐Stop Circuit Board

Figure 3 – Posi-‐Stop Circuit Boards

GUIDE

4 Posi-‐Stop Stationary Test

a) Connect encoder and solenoid cables
b) If there is a power supply, connect the 110 VAC and use the meter to check if output is at
12.5 VDC. Turn adjustment potentiometer to get 12.5 VDC
c) Turn power switch to ON and ensure the block position LED tracks from 25 to 75, up and
down—if it does not, refer to section 6
d) Turn power switch to SET. Block position LED’s top and bottom bars should blink, and
Percent of Travel LED should show 00
e) Turn power switch to ON
f) The block position LED top bar should be on, and the percent of travel should show -‐01
g) Solenoid should be on—if not, refer to section 7
h) Red limit light should be on
i) Press red limit light bypass button
j) Red limit light should blink, and solenoid should release—if not, refer to section 7

Figure 4 – Posi-‐Stop Performing a Stationary Test

5 Posi-‐Stop Does Not Power Up
5.1 Check Incoming Power On Terminal Block
a) Connect meter red lead to the red wire

b) Connect meter black lead to black wire
c) If meter reads 12 volts, go to section 5.2
d) If meter reads less than 12V, check connection from rig external power source

Figure 5 – Checking Incoming Power Voltage Figure 6 – Position of Terminal Block in Posi-‐Stop

Note: Ground wire must go to rig battery. Do not ground to box.


GUIDE

5.2 Check Battery Voltage
a) Connect meter red lead to + side of battery

b) Connect meter black lead to – side of battery
c) Meter should read at least +12V DC
d) If voltage is below 12V, replace or recharge battery
e) If voltage is 12V or greater, go to section 5.3

Figure 7 – Checking Battery Voltage
5.3 Check Continuity Of Fuse
a) Set meter to ohms

b) Connect leads to each side of fuse
c) Meter should read zero and/or beep out
d) If fuse is good, go to section 5.4
e) If not, replace fuse

Figure 8 – Checking Fuse Continuity Figure 9 – Fuse Location on Main Board


5.4 Check Voltage To Pin Of On/Off Switch
a) Connect meter black lead to ground (pin 4) of OFF/ON/SET switch contact block
b) Connect meter red lead to pin 2 of contact block
c) Meter should read +12V DC
d) Remove lead from pin 2 on contact block and connect to pin 1
e) Meter should read zero
f) Turn Posi-‐Stop On
g) Meter should read +12V DC
h) If meter reads 12V, go to section 5.5
i) If meter does not read 12V, return Posi-‐Stop to Position Tracking Systems for repair
(see next page for images)

GUIDE

Figure 10 – Location of On/Off Switch Contact Block Figure 11 – Pin Locations on Contact Block

Figure 12 – Black Lead To Ground, Pin 4, Red to Pin 2, Figure 13 – Black Lead to Ground, Pin 4, Red to Pin 1,
Showing 12 Volts Showing 0 Volts

Figure 14 – After Turning Box On, Meter Reads 12 Volts


5.5 Check Voltage Located At TB Top Of Main Board Above Fuse
a) Connect meter red lead to red wire

d) If meter reads 12V, skip to section 5.6
e) If meter does not read 12V, return Posi-‐Stop to Position Tracking Systems for repair

Figure 15 – Checking TB Voltage Figure 16 – TB Location on Main Board

GUIDE

5.6 Check Voltage Readings On 7805 At Top Of Main Board
a) Connect black lead to metal top of 7805

b) Connect red lead to left leg of 7805
d) Connect red lead to right leg of 7805
e) Meter should read +5V DC
f) If above test fails, return Posi-‐Stop to Position Tracking Systems for repair

Figure 17 – Red Lead to Left Leg Figure 18 – Red Lead to Right Leg

Figure 19 – Location of 7805 on Main Board

6 Posi-‐Stop Powers Up, LED Displays Do Not Function
6.1 Check voltage on LED board
a) Connect meter red lead to red wire on terminal block located at top of LED board
d) If meter reads 12V, go to section 6.2
e) If no voltage, perform steps in section 5.5
f) If still not getting 12V, return Posi-‐Stop to Position Tracking Systems for repair

Figure 20 – Checking Voltage on LED Board Figure 21 – TB Location on LED Board


GUIDE

6.2 Check The 7805 On The LED Board
a) Connect meter black lead to metal top of 7805

b) Connect meter red lead to left leg of 7805
d) Connect meter red lead to right leg of 7805
e) Meter should read +5V DC
f) If meter reads correctly, go to section 6.3
g) If above test fails, return Posi-‐Stop to Position Tracking Systems for repair

Figure 22 – Steps a-‐c Figure 23 – Steps d-‐f
6.3 Check 12 Volt TB Coming From Main Board
a) Connect meter red lead to 12v terminal block on main board
b) Connect meter black lead to ground terminal block on main board
c) If meter reads 12 volts, and display still does not function, return Posi-‐Stop to Position
Tracking Systems for repair

Figure 24 – Steps a-‐b Figure 25 – Location of TB on Main Board

7 Solenoid Does Not Function Correctly
7.1 Check Voltage To Solenoid
a) Turn Posi-‐Stop on

b) Turn switch to SET
c) Turn switch back to ON
d) When solenoid activates, red limit light should come on (Solenoid should make an audible
“click”)
e) Connect red lead of meter to white wire located on right side of main board
f) Connect black lead of meter to black wire
g) Meter should read +12V DC
h) Press red limit light Bypass button, solenoid should release (Solenoid should make an
audible “click”)
i) Voltage should go to 0V DC
j) Red limit light should flash
k) If bullets a) through j) function as specified, go to section 7.2

Figure 26 – Steps e-‐g Figure 27 – Steps i-‐j

Figure 28 – Flashing Limit Light on Posi-‐Stop

GUIDE

7.2 Check Connection In Junction Box On Solenoid
a) Remove solenoid junction box cover

b) Ensure the two black wires from the solenoid have good connection with the black and
white wires in the yellow cable from the Posi-‐Stop
c) Connect the cable to the Posi-‐Stop (Yellow three conductor cable marked “solenoid”)
d) Turn Posi-‐Stop to ON, then SET, then ON
e) Solenoid should activate, red limit light should turn on (Solenoid should make audible
“click”)
f) Connect red lead from meter to white wire. Connect black lead from meter to black wire.
g) Meter should read 12V DC. If less than 10V solenoid will not operate.
h) Press red limit light Bypass button
i) Solenoid should release, red limit light should blink (Solenoid should make audible “click”)
j) Voltage reading should be 0
k) Repeat steps a) through g) in section 7.1
l) If solenoid does not activate, replace solenoid

Figure 29 – Voltage Check Between White + Black Figure 30 –Voltage Check After Pressing Bypass

Figure 31 – Location of Wires in Solenoid

7.3 New Style Solenoid Valve Functional Test
a) Connect new style solenoid to Posi-‐Stop (Yellow three conductor cable marked
“solenoid”)
b) Turn Posi-‐Stop to ON – then SET – then back to ON
c) Solenoid should activate and air cylinder should operate
d) LED light on top of solenoid should be on
e) Press red limit light Bypass button – solenoid should release and air cylinder should
exhaust
f) Solenoid LED light should go off
g) If LED and solenoid do not function as specified in steps c), d), e), and f), replace solenoid

Figure 32 – Solenoid LED On Figure 33 – Solenoid LED Off

GUIDE

8 Proximity Switch or Encoder Does Not Function Correctly
8.1 Check Continuity Of Encoder/Proximity Switch Cable
a) Perform continuity test on corresponding pins on each end of cable
b) If cable does not test correctly, replace or return cable to Position Tracking Systems for
repairs
c) If cable does test correctly, for an encoder system, send encoder to Position Tracking
Systems for repairs
d) If cable does test correctly, for a proximity switch system, go to section 8.2

Figure 34 – Checking Continuity of Cable


8.2 Proximity Switch Installation/Tests
8.2.1 Check Sensor Installation
a) Hopper rig installation:

1) Ensure the 16 targets are 4” apart and ¼” below the flange edge
2) Ensure that sensor is properly mounted. A sturdy location limits vibrations that
may impact the encoder’s ability to accurately sense the targets. Add gussets or
additional support if needed. The sensor bracket must be positioned such that the
tips of the sensors are ¼” away from the targets and 1/8” from the outside edge
of the target (away from the flange).
b) Franks rig installation:
1) Mount target wheel on bearing carrier housing as shown in Figure 36
2) Proximity switch bracket needs to be positioned so that the switches are located
on the target center line (centered over target holes), and the tips of the switches
need to be ¼” away from the target wheel
c) Ensure the black encoder cable is connected to the Posi-‐Stop
d) Ensure cables are protected from moving parts or accidental contact by rig personnel
e) Check yellow end of sensor to ensure it has not scraped the end by contacting target
f) If sensors are damaged, contact Position Tracking Systems for replacement
g) If sensors are good, and installation is correct, go to section 8.2.2

Figure 35 – Sensor Installation Location On Hopper Rig

Figure 36 – Sensor Installation On Franks Rig


GUIDE

8.2.2 Test Proximity Switch Sensors
a) Connect proximity switch assembly to Posi-‐Stop with encoder cable

b) Turn switch to “Set”
c) Touch sensor 1 to metal object
d) A reading of “+01” should be displayed on Posi-‐Stop
e) Touch sensor 2 to metal object
f) A reading of “+155” should be displayed on Posi-‐Stop
g) If readings are not as specified in d), and f), go to section 8.2.3
h) If readings are as specified in d), and f), and proximity switch still does not work correctly,
repeat steps in section 8.2.1

Figure 37 – Sensor 1 Making Contact Figure 38 – Sensor 2 Making Contact


8.2.3 Test Proximity Switch Sensor LEDs
a) Remove cover from proximity switch assembly

b) Connect proximity switch encoder cable to Posi-‐Stop
c) Turn Posi-‐Stop On
d) The two LED lights on proximity switch circuit board will illuminate
e) Touch one sensor to a metal surface – one LED will turn off
f) Touch the other sensor to a metal surface – the other LED will turn off
g) If steps e) and f) function as specified, the LED board and sensors are operational, go to
section 8.2.4
h) If steps e) and f) do not function as specified, send proximity switch assembly to Position
Tracking Systems for repairs

Figure 39 – One Sensor Light Off Figure 40 – Other Sensor Light Off


GUIDE

8.2.4 Test Proximity Switch Circuit Board
NOTE: Targets need to be moving very slowly past proximity switches to get accurate readings.
a) Ensure 12 volts is available to proximity switch assembly by connecting red lead from
meter to red wire and black lead from meter to green wire
b) Read 3.3V (positive or negative) by connecting meter leads to blue and orange wires
c) Also read 3.3V (positive or negative) by connecting meter leads to black and white wires
d) When proximity switch detects target, voltage should change from negative to positive
(or vice versa)
e) LED Lights on circuit board and proximity switch should alternate when proximity switch
detects target
f) Ensure voltage is going through circuit board to proximity switch by connecting meter
leads to brown and blue wires – should read 12 volts
g) Read 3.3V (positive or negative) by connecting meter leads to blue and black proximity
switch wires
h) When proximity switch detects target, voltage should change from negative to positive
(or vice versa)
i) Connect black lead from meter to metal top of 7805
j) Connect red lead from meter to left leg of 7805
k) Meter should read +12V DC
l) Connect red lead from meter to right leg of 7805
m) Meter should read +5V DC
n) If steps a) through m) are as specified, go to section 8.2.5
o) If voltage is not as specified, return proximity switch assembly to Position Tracking
Systems for repairs.

Figure 41 – 12V Coming Into Proximity Switch Figure 42 – Negative 3.3V On Blue and Orange
(see next page for more images)

Figure 43 – Positive 3.3V When Sensor On Target Figure 44 – Negative 3.3V On Black and White

Figure 45 – Positive 3.3V When Sensor on Target Figure 46 – Negative 3.3V on Blue and Black

Figure 47 -‐ Positive 3.3V When Sensor On Target Figure 48 – 7805 Location in Proximity Switch

Figure 49 -‐ Red Lead to Left Leg of 7805 Figure 50 -‐ Red Lead to Right Leg of 7805

GUIDE

8.2.5 Test Proximity Switch Sensors Through Circuit Board
a) Turn Posi-‐Stop on

b) Connect meter black lead to black wire, meter red lead to white wire on proximity switch
board
c) Meter should read 3.3V
d) Touch corresponding sensor to metal – voltage will change to negative 3.3V
e) Connect meter black lead to blue wire, meter red lead to orange wire on proximity switch
board
f) Meter should read 3.3V
g) Touch corresponding sensor to metal – voltage will change to negative 3.3V
h) If steps a) through g) are not as specified, go to section 8.3
i) If steps a) through g) are as specified, perform steps f) through m) in section 8.2.4

Figure 51 – Black Meter Lead To Black, Red Meter Lead Figure 52 – Touching Sensor To Metal Produces Negative
to White Voltage

Figure 53 -‐ Black Meter Lead To Blue, Red Meter Lead to Figure 54 -‐ Touching Sensor To Metal Produces Negative
Orange Voltage


8.3 Check Voltage at Encoder/Proximity Switch Input Terminal on Main Board
a) Connect encoder/proximity switch assembly to Posi-‐Stop with encoder cable

b) Turn on Posi-‐Stop
c) Connect meter red lead to pin 1 and meter black lead to pin 2 on terminal block at left
side of main board
d) Turn encoder/proximity switch target (slowly)
e) Meter should change from +3V to -‐3V while encoder/proximity switch target is turning
slowly
f) Connect meter red lead to pin 3 and meter black lead to pin 4 on terminal block at left
side of main board
g) Turn encoder/proximity switch target (slowly)
h) Meter should change from +3V DC to -‐3V DC while encoder/proximity switch target is
turning slowly
(see next page for images)

GUIDE

Figure 55 – Positive 3.3V on Pins 1 and 2 Figure 56 – Negative 3.3V on Encoder turn

Figure 57 – Positive 3.3V on Pins 3 and 4 Figure 58 – Negative 3.3V on Encoder turn

Figure 59 – Location of TB on Main Board, With Pins Labeled 1 through 4

Posi - Stop Troubleshooting Guide: Position Tracking Systems

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Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 3

4 POSI-­‐STOP PLUS TROUBLESHOOTING Version 1.0.0

2 Posi-­‐Stop User Interface and Connection Locations

Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 5

3 Posi-­‐Stop Circuit Board

6 POSI-­‐STOP PLUS TROUBLESHOOTING Version 1.0.0

4 Posi-­‐Stop Stationary Test

Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 7

5 Posi-­‐Stop Does Not Power Up

5.1 Check Incoming Power On Terminal Block

a) Connect meter red lead to the red wire

8 POSI-­‐STOP PLUS TROUBLESHOOTING Version 1.0.0

a) Connect meter red lead to + side of battery

5.3 Check Continuity Of Fuse

a) Set meter to ohms

Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 9

(see next page for images)

10 POSI-­‐STOP PLUS TROUBLESHOOTING Version 1.0.0

Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 11

a) Connect meter red lead to red wire

12 POSI-­‐STOP PLUS TROUBLESHOOTING Version 1.0.0

a) Connect black lead to metal top of 7805

Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 13

6 Posi-­‐Stop Powers Up, LED Displays Do Not Function

6.1 Check voltage on LED board

14 POSI-­‐STOP PLUS TROUBLESHOOTING Version 1.0.0

a) Connect meter black lead to metal top of 7805

6.3 Check 12 Volt TB Coming From Main Board

Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 15

7 Solenoid Does Not Function Correctly

7.1 Check Voltage To Solenoid

a) Turn Posi-­‐Stop on

a) Remove solenoid junction box cover

Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 17

7.3 New Style Solenoid Valve Functional Test

18 POSI-­‐STOP PLUS TROUBLESHOOTING Version 1.0.0

8 Proximity Switch or Encoder Does Not Function Correctly

8.1 Check Continuity Of Encoder/Proximity Switch Cable

Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 19

8.2.1 Check Sensor Installation

a) Hopper rig installation:

20 POSI-­‐STOP PLUS TROUBLESHOOTING Version 1.0.0

a) Connect proximity switch assembly to Posi-­‐Stop with encoder cable

Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 21

a) Remove cover from proximity switch assembly

22 POSI-­‐STOP PLUS TROUBLESHOOTING Version 1.0.0

(see next page for more images)

Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 23

24 POSI-­‐STOP PLUS TROUBLESHOOTING Version 1.0.0

a) Turn Posi-­‐Stop on

Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 25

a) Connect encoder/proximity switch assembly to Posi-­‐Stop with encoder cable

(see next page for images)

26 POSI-­‐STOP PLUS TROUBLESHOOTING Version 1.0.0

Version 1.0.0 POSI-­‐STOP PLUS TROUBLESHOOTING GUIDE 27

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a) Turn Posi-‐Stop on

Version 1.0.0 POSI-‐STOP PLUS TROUBLESHOOTING GUIDE 17

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a) Connect proximity switch assembly to Posi-‐Stop with encoder cable

Version 1.0.0 POSI-‐STOP PLUS TROUBLESHOOTING GUIDE 21

22 POSI-‐STOP PLUS TROUBLESHOOTING Version 1.0.0

Version 1.0.0 POSI-‐STOP PLUS TROUBLESHOOTING GUIDE 23

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a) Turn Posi-‐Stop on

Version 1.0.0 POSI-‐STOP PLUS TROUBLESHOOTING GUIDE 25

a) Connect encoder/proximity switch assembly to Posi-‐Stop with encoder cable

26 POSI-‐STOP PLUS TROUBLESHOOTING Version 1.0.0

Version 1.0.0 POSI-‐STOP PLUS TROUBLESHOOTING GUIDE 27