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Appendix - 1 LCS Message Lights (Error Codes) Doc_000472
Appendix LCS Message Lights (Error Codes)
REVISION 20041004

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Appendix - 1 LCS Message Lights (Error Codes)
Code Version 3.25





Figure 1 Message Lights
(023375.jpg))


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Appendix LCS Message Lights (Error Codes)
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Appendix LCS Message Lights (Error Codes)
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Overview

Since the LCS system is external to the main control system, it needs to be able to communicate to the
operator or maintenance personnel information about faults, errors, warnings, etc that have been
detected by the LCS program. This is done using Faults Lights and a Message Light that will blink a
coded message if required.

On retrofitted LCS systems the fault and message lights are located either on the main face panel if a
new boom has been retrofitted or on the boom buddy panel which is attached to the bottom of the
existing boom.




Figure 2 Retrofit & Boom Buddy Fault & Message Lights
(023375/6.jpg)

On new LCS-Series stackers where the LCS has been integrated into the machine, the message light is
located on the left side of the operator boom panel.

Figure 3 New LCS-Series Stacker Fault & Message Lights
(023379.jpg) Doc_000472
Appendix LCS Message Lights (Error Codes)
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Fault Lights

There are two faults lights:

LIGHT GUARD FAULT
this light turns on constant when a fatal fault has occurred within the Light
Guard Perimeter monitor circuit. Simply blocking the light beams will not cause this to occur. It is
normally an indicator of some sort of hardware problem such as failure for the redundant circuits to be
synchronized. Check the Message Light for a code to help determine and solve the problem.

NOTE: A LIGHT GUARD FAULT will not allow the Deck Down Enable button to RESET the light
guard system but will still allow the LCS to function in the Manual Mode (operator has to hold the Deck
Down Enable button during Load Change Cycle)

SYSTEM FAULT
this light turns on constant when a fatal fault has occurred within the Main LCS
circuitry. Check the Message Light for a code to help determine and solve the problem.

Message Light

The message light will allow 1 message to be communicated to the user. An internal priority system
makes sure that the most important message is displayed first should there be more that one error. You
will want to address the issue of the active message first, once resolved the next message will be
displayed until all message issues are resolved. Normally, there should be no message light flashing.

A quick-reference listing of the messages and error codes are posted either on the LCS Panel of and/or
the back of the boom.

A message code is determined by three sets of short pulses. After a 3 second pause with the light off,
the light will flash quickly 1-4 times, then a pause, then another 1-4 times, another pause and finally
another 1-4 times. This then is followed by the 3 second pause and the cycle is repeated.

Putting these counts together gives you an error code. For example, if after the 3 second pause you
count 1 pulse, 3 pulse, then 2 pulse your code message would be 1-3-2. The following table will then
give you a short description of the message and some additional information on possible course of
action.

Message Light
If you get a system fault or a light guard fault, the first thing that should be done is to reset the LCS
system. Press and hold the LCS RESET BUTTON located on the main LCS enclosure for 5 seconds. If
the error returns use the table below to trouble shoot the problem. Doc_000472
Appendix LCS Message Lights (Error Codes)
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ID Code Message
Type
Message Description
Errors
0 1-1-2
Information
Auto-Halt Active
Details
The stacker is going through a Load Change Cycle and wants to
extend the accumulator but cant since the operator was not holding
the Deck Down Enable button. As a result, the system automatically
went to Feed Interrupt and stopped the deck belt.
Trouble Shooting
Normally, simply pressing the Deck Down Enable button will
resume the stacker belts, the load change cycle will complete. The
operator should try to make sure that the Light Guard is reset or that
he is holding the Deck Down Enable button the next time the Load
Change Cycle is about to occur.
1 1-1-3
Error
Deck Down Enable Button Stuck
Details
There are two contacts on the Deck Down Enabled button (part of the
redundancy) that acts as a primary controlling input into the LCS
system. This error occurs should the system detect that these
contacts are closed for a substantial period of time which is greater
than normally required.
Trouble Shooting
This will keep the operator from jamming a tool into the Deck Down
Enabled button in an attempt to override the system. Make sure the
button has not been modified.
Check for shorts or other electrical wiring problems
2 1-1-4
Error
Operator Position Sensor Blocked
Details
The output of this sensor is used to make sure that the operator is
standing in front of the boom when pressing the Deck Down Enabled
button. Normally the operator may stand there for many minutes at
the most.
Trouble Shooting
This will keep the operator from taping over the sensor in an attempt
to override the system. Make sure the eye is not blocked or
modified.
Check for other electrical wiring problems that would simulate the
eye being covered.
3 1-2-2
Error
Light Guard: Top Beam: Initialization Failed
Details
On first power up the pulsing of the top beam the PLC input from the
Top Beam never went off.
Trouble Shooting
Check all emitters in the Top Beam to make sure they are pulsing.
The Top Beam starts on the drive side of the machine. Doc_000472
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4 1-2-3
Error
Light Guard: Bottom Beam: Initialization Failed
Details
On first Power Up the pulsing of the Bottom beam the PLC input
from the Top Beam never went off.
Trouble Shooting
Check all emitters in the Bottom Beam to make sure they are pulsing.
The Bottom Beam start on the Operator side of the machine.

5 1-2-4
Error
Light Guard: Top Beam: Pulse Test Failed
Details
During pulsing of the top beam the PLC input from the Top Beam
never went off.
Trouble Shooting
Check all emitters in the Top Beam to make sure they are pulsing.
The Top Beam starts on the drive side of the machine.

6 1-2-5
Error
Light Guard: Bottom Beam: Pulse Test Failed
Details
During the pulsing of the Bottom beam the PLC input from the Top
Beam never went off.
Trouble Shooting
Check all emitters in the Bottom Beam to make sure they are pulsing.
The Bottom Beam start on the Operator side of the machine

7 1-3-1
Error
Asynchronous LCS Safety Valves
Details
When the Deck Down Enable Reset Light Guard button was push one
of the contactors did not receive power. This error will go away after
10 seconds.
Trouble Shooting
Make sure the button is being push in all the way. Check all
connection in push button chain

8 1-3-3
Error
Electrical Fault:
Details
The Hardware Fault 2 relay came on.
Trouble Shooting
This relay is powered by the Fault TDR relay. Check to make sure
FLT TDR is on if it is see the error above for trouble shooting tips. If
the FLT relay is not on check contact on the HFLT2 relay or replace
relay.

9 1-3-4
Error
PCB Fault, Not Seeing PLC Watchdog
Details
The LCS Hardware Test Board is giving the PLC an input indicating
it is not receiving a watchdog signal from the PLC.
Trouble Shooting
Check terminal 866 and 867 to 0v. There should be 24 volts on those
terminals that get pulsed off every second for about 20 ms. If those
signals are present check Terminal J4-3 on the PCB to 24 volts, the
PCB should be pulling this terminal down to 0V and check input 23
on the PLC Main CPU. If there is no voltage and the input is off,
replace the PCB.
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Appendix LCS Message Lights (Error Codes)
REVISION 20041004

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10 1-3-5
Error
PCB Light Guard Fault
Details
The LCS Hardware Test Board is giving the PLC an input indicating
that the light beams are not functioning properly.
Trouble Shooting
Check to see if all the Emitters are pulsing. If they are check to see if
CR41 is energized in the LCS control cabinet. If CR41 is energized
the PLC is not indicating there is a light guard fault and the PCB
needs to be replaced.
11 2-1-1
Error
Operator Side Top Limit Not Made
Details
The LCS PLC is not receiving an operator side top limit input when
trying to perform the safety valve test.
Trouble Shooting
Be sure the stacker is jogged all the way up. Then check to see if limi