installation manual 5 volt or 15 volt communication signal

© 2015 Valmont Industries, Inc., Valley, NE 68064 USA. All rights reserved. www.valleyirrigation.com
Variable Rate Irrigation Zone Option
Installation Manual 0998114_C
Variable Rate Irrigation Option with 5 Volt or 15 Volt Communication Signal Installation Manual
5 Volt or 15 Volt
Communication Signal
DRAFT COPY DRAFT COPY
Variable Rate Irrigation Option with 5 Volt or 15 Volt Communication Signal Installation Manual ........... 1 Table Of Contents ............................................................................................................................................. 3 General Information ......................................................................................................................................... 4
About This Manual ......................................................................................................................................... 5 Tools Needed ................................................................................................................................................ 5
Safety ................................................................................................................................................................. 7 Recognize Safety Information ....................................................................................................................... 7
Safety Messages ........................................................................................................................................ 7 Information Messages ................................................................................................................................ 7
Use of Personal Protective Equipment .......................................................................................................... 8 Conductive Materials and Equipment ............................................................................................................ 8 Fall Protection ................................................................................................................................................ 8 Minimum Working Clearance ........................................................................................................................ 9 Qualified Person ............................................................................................................................................ 9 Overhead Power Lines ................................................................................................................................ 10 Minimal Lockout / Tagout Procedure ........................................................................................................... 11
Sequence of Lockout ................................................................................................................................ 11 Restoring Equipment to Service ............................................................................................................... 11
Installation Instructions ................................................................................................................................. 13 Disconnect All Power ................................................................................................................................... 13 Install Power Line Carrier In Control Panel .................................................................................................. 14
5 Volt Communication Signal - Install Power Line Carrier ......................................................................... 14 15 Volt Communication Signal - Install Power Line Carrier ....................................................................... 15 Set Control Panel Power Line Carrier Dip Switches ................................................................................. 16
Install VRI-Zone Last Tower Box .................................................................................................................. 17 Set VRI-Zone Last Tower Box Sync Pattern Dip Switches ........................................................................ 17 Set VRI-Zone Last Tower Box ID Dip Switches ......................................................................................... 18 Identify Sprinkler Bank Solenoids ............................................................................................................. 18 Temporary VRI-Zone Last Tower Box Electrical Connection..................................................................... 19
Temporary Connection to Control Panel ................................................................................................ 19 Temporary Connection to Collector Ring ............................................................................................... 20 Temporary Tower Box Position ............................................................................................................... 20 Turn Power On ....................................................................................................................................... 20
Verify Control Panel Software ...................................................................................................................... 21 Upgrade Control Panel ................................................................................................................................ 21 Setup Control Panel for GPS Position ......................................................................................................... 21
Estimated Drive Unit Speed Table ............................................................................................................ 21 Pro2 Control Panel v8.40 or v9.01 and Later Setup-Set Current Method ................................................. 22 TouchPro Control Panel v9.02 and Later Setup-Set Current Method ....................................................... 23 Permanently Install Tower Box .................................................................................................................. 25
Disconnect All Power ............................................................................................................................. 25 Disconnect Tower Box ............................................................................................................................ 26 Install Tower Box .................................................................................................................................... 26
Install VRI Intermediate Tower Boxes .......................................................................................................... 27 Disconnect All Power ................................................................................................................................ 27 Install Tower Boxes ................................................................................................................................... 28
Bracket Mounting ................................................................................................................................... 28 Span Pipe Mounting ............................................................................................................................... 28
Set Tower Box Sync Pattern Dip Switches ................................................................................................ 29 Set Tower Box ID Dip Switches ................................................................................................................. 30 Identify Sprinkler Bank Solenoids ............................................................................................................. 31
Install Sprinkler Valves ................................................................................................................................ 31 Install Water Filter (Optional) ....................................................................................................................... 31 Install Stand Pipe (Optional) ........................................................................................................................ 32 Install Sprinkler Bank Tubing Harnesses ..................................................................................................... 33 Install Strain Relief Fittings .......................................................................................................................... 34 Wire Variable Rate Tower Boxes .................................................................................................................. 34
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Field Install And Wiring Diagrams ................................................................................................................ 35 Decal Dip Switch Settings for Power Line Carrier pn 0998384 ................................................................... 36 Field Install Dip Switch Settings pn 9311996 .............................................................................................. 37 Field Wiring VRI Intermediate Tower Box pn 9311842 ................................................................................ 38 Decal Wiring Schematic VRI Intermediate Tower Box pn 0998385 ............................................................. 39 Field Install Stand Pipe Option pn 9311843 ................................................................................................ 40 Field Install Data Port Programming Cable pn 9311846 ............................................................................. 41 5 Volt communications
Pro2 Field Wiring Power Line Carrier 5 Volt Comm Signal to Control Panel pn 9311777 ......................... 42 TouchPro v9.02 Field Wiring Power Line Carrier 5 Volt Comm Signal to Control Panel pn 9311856_D ... 43 Field Wiring VRI 5 Volt Communications Signal Last Tower Box pn 9311844 .......................................... 44 Decal Wiring Schematic VRI 5 Volt Communications Signal Last Tower Box pn 0998386 ....................... 45
15 Volt Communications Pro2 Field Wiring Power Line Carrier 15 Volt Comm Signal to Control Panel pn 9311829 ....................... 46 TouchPro v9.02 Field Wiring Power Line Carrier 15 Volt Comm Signal to Control Panel pn 9311859_C . 47 Field Wiring VRI 15 Volt Communications Signal Last Tower Box pn 9311845 ........................................ 48 Decal Wiring Schematic VRI 15 Volt Communications Signal Last Tower Box pn 0998387 ..................... 49
Setup ................................................................................................................................................................ 51 Setup Variable Rate Irrigation Zone Option Pro2 8.40 or Higher ............................................................... 51 Setup Variable Rate Irrigation Zone Option - TouchPro v9.02 or Higher ..................................................... 52
Testing ............................................................................................................................................................. 53 Pro2 ............................................................................................................................................................. 53
Test and Adjust GPS Position ................................................................................................................... 53 Test Variable Rate Irrigation ...................................................................................................................... 54
TouchPro ..................................................................................................................................................... 55 Test and Adjust GPS Position ................................................................................................................... 55 Test Variable Rate Irrigation ...................................................................................................................... 56
Troubleshooting .............................................................................................................................................. 57 System Faults .............................................................................................................................................. 57
Viewing System Faults .............................................................................................................................. 58 Error Codes ................................................................................................................................................. 59
Viewing An Error Code ............................................................................................................................. 60 Fuse Testing ............................................................................................................................................... 61 Power Supply Testing .................................................................................................................................. 61 Serial Cable Shielded DB25 To RJ-11 03E2781 - Pin Call Out ................................................................... 62 Using Different Modems on Same Machine ................................................................................................ 62
Version 1 Modem Card - Pin/Terminal Call Out/Dip Switch ...................................................................... 63 Version 2 Modem Card - Pin/Terminal Call Out/Dip Switch ...................................................................... 63
GPS Receiver Accuracy .............................................................................................................................. 64 GPS Signal Errors ....................................................................................................................................... 64 GPS Antenna Testing ................................................................................................................................. 65 Verify Proper Installation of VRI Tower Boxes and Dip Switch Settings....................................................... 66 Making A Garmin 17X or 19X GPS Setup Receiver (Optional) ................................................................... 67 Connecting / Using GPS 17X or 19X Setup Receiver (Optional) ................................................................ 68 Setup Control Panel for GPS Position ........................................................................................................ 69
Pro2 v8.40 or Higher using EDIT .............................................................................................................. 69 TouchPro Control Panel v9.02 and Higher using EDIT ............................................................................. 71
GPS Angular Conversion Table ................................................................................................................... 73 Angular Degree Examples .......................................................................................................................... 73 Estimated Drive Unit Speed Table ............................................................................................................... 74 Garmin 17x or 19x GPS Power Data Cable Wire Color/Function ................................................................ 74
5
About This Manual This manual illustrates the proper installation of the Variable Rate Irrigation Zone Option (VRI Zone) on a Valley pivot irrigation machine that is equipped with a Valley Pro2 control panel software version 8.40 or higher or TouchPro v9.02 or higher.
NOTE • The Variable Rate Irrigation Option with 5 Volt Communication Signal is not designed for use with the Precision Corner or other applications that may interfere with the power line carrier signal. For applications where signal interference is a problem the Variable Rate Irrigation Option with 15 Volt Communication Signal should be installed.
Specifications, descriptions and illustrative material contained in this manual were based on information available at the time this publication was approved for printing. Valmont Industries Inc. reserves the right to change specification or design at any time without notice and without incurring any obligation. Specifications are applicable to equipment sold within the United States and may vary outside of the United States.
! WARNING • THE ASSEMBLY OF THESE COMPONENTS, INCLUDING ADJUSTING, TESTING AND TROUBLE- SHOOTING SHOULD BE PERFORMED ONLY BY AN AUTHORIZED VALLEY DEALER.
• IF ANY WIRE IS NOT CONNECTED TO A TERMINAL OR COMPONENT IN THE CONTROL PANEL, PROTECT THE END OF THE WIRE WITH A WIRE NUT OR EQUIVALENT TO PREVENT DAMAGE FROM SHORT CIRCUIT OR ARCING.
Tools Needed • Flat blade screw drivers • Phillips head screw drivers • 1/2 Sockets and/or Wrenches
• 3/4 Sockets and/or Wrenches • Adjustable wrench • Pipe wrenches • Water pump pliers
Garmin® is a registered trademark of Garmin Ltd. or its subsidiaries.
• Latest Pro2 or TouchPro Software • Laptop Computer
Parts ................................................................................................................................................................. 75 5 Volt Communication Signal
Panel PLC and Last Tower Box 5 Volt Communication Signal - Variable Rate Irrigation .......................... 77 Pro2 PLC for Control Panel - 5 Volt Communication Signal ...................................................................... 78 TouchPro PLC for Control Panel - 5 Volt Communication Signal .............................................................. 79 Tower Box - Intermediate - 5 Volt Communication Signal - Variable Rate Irrigation ................................. 80 Tower Box - Last - 5 Volt Communication Signal - Variable Rate Irrigation ............................................... 82
15 Volt Communication Signal Panel PLC and Last Tower Box 15 Volt Communication Signal - Variable Rate Irrigation ........................ 84 Pro2 PLC for Control Panel - 15 Volt Communication Signal .................................................................... 85 TouchPro PLC for Control Panel - 15 Volt Communication Signal ............................................................ 86 Tower Box - Intermediate - 15 Volt Communication Signal Variable Rate Irrigation ................................. 88 Tower Box - Last - 15 Volt Communication Signal Variable Rate Irrigation ............................................... 90
Additional Components Tower Box Drive Unit Mount - Variable Rate Irrigation .............................................................................. 92 Water Filter - Variable Rate Irrigation ........................................................................................................ 93 Water Application - Variable Rate Irrigation .............................................................................................. 94 2 Drop Valve with Fittings - Variable Rate Irrigation .................................................................................. 95 Tower Box - Pipe Mounting - Variable Rate Irrigation ............................................................................... 96 Stand Pipe Options ................................................................................................................................... 98 Stand Pipe Mounting Kit .......................................................................................................................... 99 Half Clamp Mounting Kits ....................................................................................................................... 100 Program Cable - Variable Rate Irrigation ................................................................................................ 101
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SAFETY
7
Recognize Safety Information This irrigation equipment can be powered by high voltage, which can be extremely dangerous if used improp- erly. For maximum safety and optimum performance of the machine, all owner/operators and maintenance personnel must read and understand the owner/operator manual(s), all safety messages in this manual and safety signs/decals on the machine before operating this equipment.
Anyone assembling, operating, servicing or maintaining this machine must read and understand all operation, maintenance, troubleshooting, testing, installation, assembly instructions and all safety messages in this manual before operating the machine or beginning any maintenance, troubleshooting, testing, installation or assembly of components.
These instructions alert you to certain things you should do carefully; if you don’t, you could hurt yourself or others, hurt the next person who operates the equipment, or damage the equipment.
Safety Messages Safety messages in this manual are preceded by the hazard symbol and one of three words: DANGER, WARN- ING or CAUTION. These messages alert you to potential hazards that could hurt you or others and or cause property damage.
! This HAZARD SYMBOL is used to alert you to information about unsafe actions or situations, and may be followed by the word DANGER, WARNING or CAUTION.
! DANGER The HAZARD SYMBOL used with the word DANGER describes immediate hazards that can result in severe personal injury or death.
! WARNING The HAZARD SYMBOL used with the word WARNING describes unsafe actions or situations that can result in severe injury, death and/or major equipment or property damage.
! CAUTION The HAZARD SYMBOL used with the word CAUTION describes unsafe actions or situations that can result in injury, and/or minor equipment or property damage.
Information Messages Important information messages in this manual are preceded by the word NOTE.
NOTE The word NOTE is used to alert you to information that describes procedures or tips to help you install, operate or maintain your equipment properly.
SAFETY
8
Use of Personal Protective Equipment • People working in areas where there are potential electrical hazards must use, personal protective equipment
that is appropriate for the specific parts of the body to be protected and for the work to be performed. Refer to U.S. Occupational Safety & Health Administration (OSHA) Regulations (Standards - 29 CFR) Safeguards for personnel protection. - 1910.335, or applicable national, state or local regulations, for additional information.
• Personal protective equipment must be maintained in a safe, reliable condition and periodically inspected or tested.
• Protective shields, protective barriers, or insulating materials must be used to protect each person from shock, burns, or other electrically-related injuries while that person is working near exposed energized parts which might be accidentally contacted or where dangerous electric heating or arcing might occur. When normally en- closed live parts are exposed for maintenance or repair, they must be guarded to protect unqualified persons from contact with the live parts.
• Safety signs and tags. Safety signs, safety symbols, or accident prevention tags must be used where necessary to warn people about electrical hazards which may endanger them.
Conductive Materials and Equipment Materials and equipment that can conduct electricity must be handled in a way that will prevent them from contacting energized power lines, exposed conductors or circuit parts.
• When handling long conductive objects (such as but not limited to truss rods, pipes, angles and ladders) in areas with energized power lines, exposed conductors or circuit parts, work practices (such as the use of insulation, guarding, and material handling techniques) must be used to minimize the hazard.
• Portable ladders must have non-conductive side rails.
• Do not wear conductive articles of jewelry and clothing (such as but not limited to watch bands, bracelets, rings, key chains, necklaces, metalized aprons, cloth with conductive thread, or metal headgear) that could come in contact with energized power lines, exposed conductors or circuit parts.
Fall Protection Identify potential fall hazards and determine if fall protection equipment is appropriate for the task, before beginning the work. Pay attention to hazards associated with routine and non-routine tasks. Inspect fall protection equipment (harnesses, lanyards) and devices (guardrails, tie-off points) before each use. Use fall protection equipment if required for the job. Be sure the fall protection equipment is right for the task, fits properly, and is in good condition. Refer to U.S. Occupational Safety & Health Administration (OSHA) Regulations Standards - 29 CFR 1926.500, 1926.501 and 1926.502, or applicable national, state or local regulations for more information.
• When using scaffolds, make sure there is proper access, full planking, stable footing, and guard railing.
• When using a boom lift, keep feet firmly on the platform of a boom lift, use fall protection equipment tied-off at all times to the guardrail or tie-off point.
• When using a ladder, make sure the ladder is non-conductive and the correct size for the task. Read the ladder user instructions and be sure the ladder is in good condition. Make sure ladder is set on stable footing and at the correct angle.
SAFETY
9
Minimum Working Clearance To reduce the risk of injury, all persons require adequate working clearance around the electrical panel or other electrical equipment. The table below identifies the minimum working clearance needed. Refer to U.S. Occupa- tional Safety & Health Administration (OSHA) Regulations (Standards - 29 CFR) Safeguards for personnel protection. -1910.303(g)(1)(i), or any other applicable national, state or local regulations, for additional information.
MINIMUM WORKING CLEARANCE 0-600 VOLTS
WIDTH OF WORKING CLEARANCE
SPACE AND NO LIVE GROUNDED PARTS ON
THE OTHER SIDE.
SPACE AND LIVE GROUNDED PARTS ON
THE OTHER SIDE.
EXPOSED LIVE PARTS ON ONE SIDE OF WORK SPACE AND EXPOSED LIVE PARTS ON THE
OTHER SIDE.
ENCLOSURE, WHICH EVER IS
Concrete, brick or tile walls shall be considered as grounded.
Qualified Person A Qualified Person is one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training, and experience, has successfully demonstrated his/her ability to solve or resolve problems related to the subject matter, the work, or the project.
Only qualified persons may work on electric circuit parts or equipment that have not been de-energized.
Refer to U.S. Occupational Safety & Health Administration (OSHA) Regulations Standards - 29 CFR 1926.32(m) and 1910.333, or applicable national, state or local regulations for additional information.
SAFETY
10
Overhead Power Lines Assembling, towing or transporting irrigation machine components such as but not limited to the pivot point, linear cart, span/drive unit assemblies, overhangs and/or corner assemblies underneath or near power lines is extremely dangerous because of the risk of electrocution.
Operating equipment that elevates irrigation machine components, such as but not limited to an aerial lift or crane, near power lines is extremely dangerous because of the risk of electrocution. Only qualified personnel should operate this type of equipment. Before operating the equipment, qualified personnel must read the equipment manufacturers’ operating and safety instructions.
Refer to U.S. Occupational Safety & Health Administration (OSHA) Regulations (Standards - 29 CFR) Cranes and derricks. - 1926.550, or any other applicable national, state or local regulations for additional information.
• Always presume that any overhead power line is an energized line unless and until the person(s) owning the line and/or the electrical utility authorities indicate that it is not an energized line and it has been visibly grounded.
• Before operating any equipment near any power line make sure the line has been de-energized and visibly grounded at the point of work.
• Electrocution can occur without touching an electrical power line. Electricity, depending on the magnitude, can jump or become induced into equipment or conductive materials that come in close proximity to, but do not touch a power line. High wind, lightning, wet ground and other environmental conditions will increase the possibility of electrocution and require additional consideration.
• Transmitter towers can induce the equipment or materials being handled with an electrical charge. Before working or operating equipment near transmitter towers, make sure the transmitter is de-energized.
• Select the location where the span/drive unit will be assembled to ensure that neither the irrigation machine, or the equipment used during the assembly process, will violate the minimum clearance guidelines.
• Never operate equipment or allow the load, ropes or tag lines within 10 ft (3.05 m) of any power line rated 50 kV or lower whether it is energized or not. For lines rated over 50 kV, the minimum clearance shall be 10 ft (3.05 m) plus 0.4 inch (1.1 cm) for each kV over 50 kVs.
• Never assemble, tow, transport or allow irrigation machine components underneath or within 10 ft (3.05 m) of any power line rated 50 kV or lower whether it is energized or not. For lines rated over 50 kV, the minimum clearance shall be 10 ft (3.05 m) plus 0.4 inch (1.1 cm) for each kV over 50 kVs. Overhang support angles, cables and spinner drive components regularly extend 10 ft to 12 ft (3.1 m to 3.7 m) above the irrigation pipeline (span).
• Use barricades to identify areas where interference with overhead power lines could occur. Keep the assembly, towing or transporting of irrigation machine components and the operation of equipment including load, ropes or tag lines away from any power line, in the distances described above, whether the line is energized or not.
• Always designate a person to observe clearance between the power line and all equipment being operated or moved in order to give timely warning for all operations to STOP if the minimum clearance is violated.
SAFETY
11
Minimal Lockout / Tagout Procedure The following procedure establishes the minimum requirements for the lockout of energy isolating devices whenever maintenance or servicing is done on machines or equipment. It is used to ensure that the machine or equipment is stopped, isolated from all potentially hazardous energy sources and locked out before personnel perform any servicing or maintenance where the unexpectedly energized or start-up of the machine or equipment or release of stored energy could cause injury. All personnel, upon observing a machine or piece of equipment which is locked out to perform servicing or maintenance shall not attempt to start, energize, or use that machine or equipment.
When the energy isolating devices are not lockable, tagout should be used and affected personnel must wear full personal protection.
Refer to U.S. Occupational Safety & Health Administration (OSHA) Regulations (Standards - 29 CFR) Typical minimal lockout procedures - 1910.147 App A, or applicable national, state or local regulations, for additional information.
Sequence of Lockout 1. Notify all affected personnel that servicing or maintenance is required on a machine or equipment and that
the machine or equipment must be shut down and locked out to perform the servicing or maintenance.
2. The authorized personnel shall identify the type and magnitude of the energy that the machine or equipment utilizes, shall understand the hazards of the energy, and shall know the methods to control the energy.
3. If the machine or equipment is operating, shut it down by the normal stopping procedure (depress the stop button, open switch, close valve, etc.).
4. De-activate the energy isolating device(s) so that the machine or equipment is isolated from the energy source(s).
5. Lock out the energy isolating device(s) with assigned individual lock(s).
6. Stored or residual energy (such as that in capacitors, springs, elevated machine members, rotating fly- wheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down, etc.
7. Ensure that the equipment is disconnected from the energy source(s) by first checking that no personnel are exposed, then verify the isolation of the equipment by operating the push button or other normal operating control(s) or by testing to make certain the equipment will not operate. CAUTION: Return operating control(s) to neutral or “off” position after verifying the isolation of the equipment.
8. The machine or equipment is now locked out.
! DANGER • WHEN PERSONNEL WILL BE EXPOSED TO CIRCUIT ELEMENTS AND ELECTRICAL PARTS, A QUALIFIED PERSON MUST USE TEST EQUIPMENT TO VERIFY THAT THE CIRCUIT ELEMENTS AND EQUIPMENT PARTS OF THE EQUIPMENT ARE DE-ENERGIZED.
Restoring Equipment to Service When the servicing or maintenance is completed and the machine or equipment is ready to return to normal operating condition, the following steps shall be taken:
1. Check the machine or equipment and the immediate area around the machine to ensure that non-essential items are removed and that the machine or equipment components are operationally intact.
2. Check the work area to ensure that all personnel are safely positioned or removed from the area.
3. Verify that the controls are in neutral.
4. Remove the lockout devices and re-energize the machine or equipment.
5. Notify affected personnel that the servicing or maintenance is completed and the machine or equipment is ready to be used.
SAFETY
12
13
INSTALLATION INSTRUCTIONS
! DANGER • THE CONTROL PANEL CONTAINS HIGH VOLTAGE! LIVE VOLTAGE CAN KILL.
• ALWAYS DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR PERFORMING MAINTE- NANCE TO THE MACHINE.
• INSTALLATION OF THIS KIT, INCLUDING TESTING AND TROUBLESHOOTING SHOULD BE PER- FORMED ONLY BY AN AUTHORIZED VALLEY DEALER.
• ALWAYS REPLACE ANY GUARDS OR SHIELDS THAT ARE REMOVED FOR PERFORMING MAINTE- NANCE.
Disconnect All Power Follow the MINIMAL LOCKOUT/TAGOUT PROCE- DURE located in the SAFETY section of this manual and do the following:
1. SHUT OFF and LOCK the public power service disconnect to the irrigation machine. FILL OUT the blue (OSHA safety color code) tag and attach to the disconnect after locking. See figure 13-1.
2. SHUT OFF the control panel main power disconnect and open the control panel inner door. See figure 13-2.
3. Determine if a power Line carrier (PLC) has al- ready been installed in the control panel.
• If a Power Line Carrier option (PLC) was previously installed, all existing PLCs on the machine must be updated with new firmware.
» Obtain the latest PLC firmware from the Valmont Service department.
» Install firmware in all existing PLCs (control panel and tower boxes).
» Continue with Set Control Panel Power Line Carrier Dip Switches on page 16.
• If a PLC has not been installed, continue with one of the following depending on application:
» 5 Volt Communication Signal - Install Power Line Carrier on the next page.
» 15 Volt Communication Signal - Install Power Line Carrier on page 15.
OFF
ON
1
2
14
INSTALLATION INSTRUCTIONS Install Power Line Carrier In Control Panel 5 Volt Communication Signal - Install Power Line Carrier 1. The power line carrier and power supply come
factory wired and attached to a din rail.
Remove power line carrier and power supply from the factory supplied din rail.
2. Attach power line carrier and power supply to existing din rail in control panel. See figure 14-1.
3. Wire power supply to control panel terminal strip and ground as shown. See Figure 14-2. Refer to the FIELD INSTALL AND WIRING DIAGRAMS section as needed.
4. Connect the serial cable. Refer to the FIELD INSTALL AND WIRING DIAGRAMS section as needed.
• For Pro2 connect the DB25 male end of serial cable to the 25-pin port on side of module. See figure 14-3.
• For TouchPro v9.02 (requires Pro2 harness pn 03E3765) connect the DB9 male end of serial cable to the DB9 female connector on the Pro2 harness. Refer to field install 9311856_D.
5. Position serial cable in existing flat clamp on control panel inner door and use two wire tie holders and wire ties to secure serial cable to the inner door. See Figure 14-3.
6. Continue with Set Control Panel Power Line Car- rier Dip Switches on page 16.
1 2
3. Din Rail
3. Ground Terminal Strip
3. 25-Pin Port 4. Module
5. Flat Clamp 6. Wire Tie Holder
7. Wire Tie
15
INSTALLATION INSTRUCTIONS Install Power Line Carrier In Control Panel 15 Volt Communication Signal - Install Power Line Carrier 1. The filter, power line carrier and power supply
come factory wired and attached to a din rail.
Remove filter, power line carrier and power supply from the factory supplied din rail.
2. Attach filter, power line carrier and power supply to existing din rail in control panel. Then install 15 Volt Communications Signal Decal below PLC. See figure 15-1.
3. Wire filter and power supply to control panel terminal strip and ground as shown. Refer to the FIELD INSTALL AND WIRING DIAGRAMS section as needed. See figure 15-2.
4. Connect the serial cable. Refer to the FIELD INSTALL AND WIRING DIAGRAMS section as needed.
• For Pro2 connect the DB25 male end of serial cable to the 25-pin port on side of module. See figure 15-3.
• For TouchPro v9.02 (requires Pro2 harness pn 03E3765) connect the DB9 male end of serial cable to the DB9 female connector on the Pro2 harness. Refer to field install 9311859_C.
5. Position serial cable in existing flat clamp on control panel inner door and use two wire tie holders and wire ties to secure serial cable to the inner door. See Figure 15-3.
6. Continue with Set Control Panel Power Line Car- rier Dip Switches on the next page.
REMOVE YELLOW W/RED AND CONNECT TO WIRE FROM FILTER J3 TERMINAL - L
2 3
4
1
5
Figure 15-1 1. Filter 2. Power Line Carrier 3. Power Supply
4. Din Rail 5. 15V Comm Sig Decal
2
3
4
1
Figure 15-2 1. Filter 2. Power Supply
3. Terminal Strip 4. Ground Terminal Strip
2
5
1
3
676
4
7
2
3. 25-Pin Port 4. Module
5. Flat Clamp 6. Wire Tie Holder
7. Wire Tie
16
INSTALLATION INSTRUCTIONS Install Power Line Carrier In Control Panel (Continued) Set Control Panel Power Line Carrier Dip Switches 1. Setting the sync pattern dip switches number 5,
6, 7 and 8 is optional depending on application.
The sync pattern for each circuit board is factory set to sync pattern #1. All circuit boards on one individual machine must use the same sync pattern. See figure 16-1.
When more than one machine uses a single power source, a different sync pattern must be used for each individual machine. The circuit board supports the use of up to 16 machines on a single power source with 16 different sync pat- terns. See figure 16-1.
NOTE • When using Version 1 modem cards with the Version 2 modem card on the same system take note of the following:
• The Version 1 modem card firmware must be updated in order to communicate with the Version 2 modem card.
• The Version 1 modem card cannot communicate with the Version 2 modem card when dip switch synchronization settings 5 through 16 are used. See figure 16-1.
2. Verify that all I.D. number dip switches number 1, 2, 3 and 4 are set to OFF. See figure 16-1.
3. Continue with Install VRI-Zone Last Tower Box on the next Page.
SYNC PATTERN #2 (OPTIONAL)
SYNC PATTERN #1 (DEFAULT)
Switches are shown in black
Version 2 Modem
and Version 2 Modem
Figure 16-1 Control Panel Power Line Carrier Dip Switch Sync Pattern Settings
17
INSTALLATION INSTRUCTIONS Install VRI-Zone Last Tower Box
Set VRI-Zone Last Tower Box Sync Pattern Dip Switches 1. Set the VRI-Zone last tower box sync pattern dip
switches number 5, 6, 7 and 8 to the same sync pattern as the control panel power line carrier. See figure 17-1.
• All circuit boards on one individual machine must use the same sync pattern. See figure 17-1.
NOTE • When using Version 1 modem card with the Version 2 modem card on the same system take note of the following:
• The Version 1 modem card cannot communicate with the Version 2 modem card when dip switch synchronization settings 5 through 16 are used. See figure 17-1.
2. Continue with Set VRI-Zone Last Tower Box ID Dip Switches on the next page.
Version 2 Modem
Figure 17-1 Power Line Carrier Dip Switch Sync Pattern Settings
18
INSTALLATION INSTRUCTIONS Install VRI-Zone Last Tower Box (Continued)
Set VRI-Zone Last Tower Box ID Dip Switches 1. Set the dip switch I.D. number for the VRI-Zone
last tower box. Up to 15 tower boxes total per machine can be identified. See figure 18-1.
(a) The 1st tower box is the one closest to the pivot point. Other tower boxes that are farther away from the pivot point are identified in nu- merical order beginning with 2nd tower box.
(b) Use a permanent marker to write the tower box ID on the outside of tower box cover
Identify Sprinkler Bank Solenoids 1. Identify and mark the sprinkler bank solenoids on
the VRI last tower box. See figures 18-2.
2. Continue with Temporary VRI-Zone Last Tower Box Electrical Connection on the next page
1ST TOWER BOXI.D. NUMBERS
Figure 18-1 Power Line Carrier Dip Switch ID Number Settings
Sol #1 Sol #2
19
INSTALLATION INSTRUCTIONS Install VRI-Zone Last Tower Box (Continued) Temporary VRI-Zone Last Tower Box Electrical Connection Use 14 gauge Green, Black and White wires, each 12 ft (3657.6 mm) long, to temporarily connect the tower box to a 120 VAC power source in the control panel or collector ring. Choose a method of connection based on the application.
• If the control panel is at the pivot point use the Temporary Connection to Control Panel on this page
• If the control panel is at a remote location away from the pivot point use the Temporary Connection to Collector Ring on the next page.
! DANGER • THE CONTROL PANEL, COLLECTOR RING AND TOWER BOXES CONTAIN HIGH VOLTAGE! 480 VOLTS CAN KILL. ALWAYS DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR PER- FORMING MAINTENANCE TO THE MACHINE.
! CAUTION • ALWAYS IDENTIFY POTENTIAL FALL HAZARDS AND DETERMINE IF FALL PROTECTION EQUIP- MENT IS APPROPRIATE FOR THE TASK, BEFORE BEGINNING THE WORK.
Temporary Connection to Control Panel 1. Remove the tower box cover.
2. Connect the wires between the following termi- nals:
(a) Green wire from tower box ground lug to control panel ground terminal strip, Ground. See figure 19-1.
(b) Black wire from tower box terminal 9 (Black) to control panel terminal 3, Line. See figure 19-1.
(c) White wire from tower box terminal 7 (White) to control panel terminal 9, Common. See figure 19-1.
3. Continue with Temporary Tower Box Position on the next page.
3 9
Control Panel
4
2
White
Black
Green
Figure 19-1 1. Ground Lug - Tower Box Ground 2. Ground Terminal Strip - Control Panel 3. Terminal 9 - Tower Box 120VAC Line 4. Terminal Strip - Control Panel 5. Terminal 7 - Tower Box (NEUT) Common
20
ring cover.
2. Connect the wires between the following termi- nals:
(a) Green wire from collector ring terminal one(1) to tower box ground lug, Ground. See figure 20-1.
(b) Black wire from collector ring terminal seven(7) to tower box fuse block, Line. See figure 20-1.
(c) White wire from collector terminal two(2) to tower box terminal block 2 (NEUT), Com- mon. See figure 20-1.
3. Continue with Temporary Tower Box Position on this page.
Temporary Tower Box Position
! CAUTION • ALWAYS IDENTIFY POTENTIAL FALL HAZ- ARDS AND DETERMINE IF FALL PROTEC- TION EQUIPMENT IS APPROPRIATE FOR THE TASK, BEFORE BEGINNING THE WORK.
1. Use a clamp to secure the tower box in position near the collector ring. See figure 20-2.
Turn Power On 2. Turn the public power service disconnect and
control panel main disconnect switch ON, the PLC board and power supply LEDs should be ON. See figure 20-3.
3. Continue with Setup Control Panel for GPS Posi- tion on the next page.
White
Black
3
2
Green1
Collector Ring
Figure 20-1 1. Green Wire to Ground-Terminal One(1) 2. Black Wire to 120V Line-Terminal Seven(7) 3. White Wire to Common-Terminal Two(2)
3 2
Figure 20-2 1. Clamp 2. Tower box 3. Collector Ring
3 9
21
INSTALLATION INSTRUCTIONS Install VRI-Zone Last Tower Box (Continued) Verify Control Panel Software 1. Verify the control panel software version and then if necessary, upgrade to the latest software version.
Listed below are the software versions available at the time this publication was approved for printing.
• Pro2 Control Panel software version 8.40 (Pro2 Hardware) or 9.02 (Pro2+ Hardware Only).
• TouchPro Control Panel software version 9.02 (Pro2+ Hardware Only).
2. If the control panel requires an upgrade continue with Upgrade Control Panel, below on this page. If not, continue with Setup Control Panel for GPS Position, below on this page.
Upgrade Control Panel To upgrade a control panel do the following:
1. Obtain the latest control panel software via Pro Flash
2. Record all the control panel constants.
3. Update the control panel with the latest software.
4. Enter all the control panel constants that were recorded before the control panel was updated.
5. Continue with Setup Control Panel for GPS Position, below on this page.
Setup Control Panel for GPS Position Setup the control panel for use with the GPS Pivot Position Option.
• Obtain the last tower speed and pivot length information from the VChart report for this machine or measure the span length from pivot to last regular drive unit not including the overhang and use the Estimated Drive Unit Speed chart. See figure 21-1.
• Measure and record the distance from the pivot point to the GPS Tower box.
• If you know the GPS coordinates for the pivot point, continue with Use Edit to Setup Control Panel for GPS Position in the Troubleshooting section. If not, continue with one of the set up procedures listed below.
Pro2 Control Panel v8.40 or v9.01 and Later Setup-Set Current Method ................................................... 22 TouchPro Control Panel v9.02 and Later Setup-Set Current Method .......................................................... 23
Estimated Drive Unit Speed Table Use this table to estimate the end drive unit speed based on the drive unit motor output RPM, tire size, and machine voltage/frequency. Drive unit speed can also be determined by measuring the distance traveled in one minute.
Estimated Drive Unit Speed Drive Unit
Motor Output RPM
Tire Sizes / Machine Voltage and Hertz
11.2 x 24 14.9 x 24 16.9 x 24 11.2 x 38
480 Volt 60Hz 380 Volt 50Hz 480 Volt 60Hz 380 Volt 50Hz 480 Volt 60Hz 380 Volt 50Hz 480 Volt 60Hz 380 Volt 50Hz
ft./min. M/min. ft./min. M/min. ft./min. M/min. ft./min. M/min. ft./min. M/min. ft./min. M/min. ft./min. M/min. ft./min. M/min.
29 5.90 1.80 4.91 1.50 6.54 1.99 5.45 1.66 6.98 2.13 5.81 1.77 8.06 2.45 6.71 2.04
30 6.10 1.86 5.08 1.55 6.77 2.06 5.64 1.72 7.22 2.20 6.01 1.83 8.34 2.54 6.95 2.12
34 6.95 2.12 5.79 1.76 7.40 2.25 6.16 1.88 8.16 2.48 6.80 2.07 9.45 2.88 7.87 2.40
35 7.12 2.17 5.93 1.81 7.89 2.40 6.57 2.00 8.42 2.56 7.01 2.14 9.73 2.96 8.11 2.47
37 7.53 2.29 6.27 1.91 8.53 2.60 7.11 2.16 8.90 2.71 7.41 2.26 10.28 3.13 8.56 2.61
43 8.75 2.66 7.29 2.22 9.91 3.02 8.26 2.51 10.34 3.15 8.61 2.62 11.94 3.64 9.95 3.03
56 11.39 3.47 9.49 2.89 12.63 3.85 10.52 3.20 13.48 4.10 11.23 3.42 15.56 4.74 12.96 3.95
58 11.80 3.59 9.83 2.99 13.08 3.98 10.90 3.32 13.96 4.25 11.63 3.54 16.12 4.91 13.43 4.09
68 13.84 4.21 11.53 3.51 15.34 4.67 12.78 3.89 16.36 4.98 13.63 4.15 18.90 5.76 15.74 4.79
69 14.03 4.27 11.69 3.56 15.57 4.74 12.97 3.95 16.60 5.05 13.83 4.21 19.18 5.84 15.98 4.86
Figure 21-1
NOTE • After GPS position is set up, the end gun settings may need to be ad- justed.
22
INSTALLATION INSTRUCTIONS Install VRI-Zone Last Tower Box (Continued) Setup Control Panel for GPS Position Pro2 Control Panel v8.40 or v9.01 and Later Setup-Set Current Method To setup the GPS position type do the following at the control panel.
1. Set percent timer to 0.0% (zero percent)
2. Set water to Off
3. Press the Start button to start the machine, energize the safety circuit and the GPS pivot position tower box
4. The GPS pivot position tower box with GPS receiver is positioned near the collector ring and wired into either the control panel or collector ring.
5. Set the 25-Pin Com Port protocol to GPS V2, press SYSTEM , 1 , 8 , 8 , 7 , 2 , 1 , 3 and 1 .
.
7. Set the Baud Rate value to 4800 baud, press ESC , ESC , 2 , and 4 .
(a) Press SYSTEM to go back to the status screen.
8. Check for satellite DGPS lock and satellite count.
(a) Press SYSTEMSYSTEM , 1 , 5 and 3 to see if the GPS receiver is locked on the DGPS satellite signal. If it is
not locked on DGPS continue waiting. Depending on location it can take 15 minutes or longer for the GPS receiver to lock on to the satellite signal and obtain DGPS accuracy. If GPS position is not working see the Troubleshooting section.
(b) Press SYSTEM to go back to the status screen.
9. Set the Pivot Point position using SET CURRENT, press SYSTEM , 1 , 5 and 1 .
(a) Press 1 , to set the Pivot Point position to the current position.
(b) Record the Pivot Point Latitude and Longitude on the inside of control panel door.
(c) Press 1 to save or 2 to cancel.
(d) Press SYSTEM
10. Set the Fallback Position Run Time, press SYSTEM
, 1 , 5 , 2 , 3 , 1 and 1 .
(a) Enter pivot speed. The default is 15.56 ft/min (4.732 m/min). Press ENTER
to retain value.
(b) Enter pivot length. The default is he default is 1320 ft (402.3 m). Press ENTER
to retain value.
(c) Press SYSTEM
to go back to the status screen.
11. Set the Distance to GPS (The distance from pivot point to GPS tower box), press SYSTEM
, 1 , 5 and 4 .
(a) Enter the length from the pivot point to the GPS receiver. Do not enter the pivot length. The default is 1320 ft (402.3 m) and the range is 10 to 6554 ft (3.0 to 1997.6 m).
(b) Press ENTER
to retain value.
(c) Enter the Plus tolerance for the length from pivot point to GPS receiver. The Default is 50 ft (15.2 m) and the range is 10 to 6554 ft (3.0 to 1997.6 m). A setting of 50 ft (15.2 m) or more is recommended to allow for variation in the GPS signal if WAAS is unavailable.
(d) Press ENTER
to retain value.
(e) Enter the Minus tolerance for the length from pivot point to GPS receiver. The Default is 50 ft (15.2 m) and the range is 10 to 6554 ft (3.0 to 1997.6 m). A setting of 50 ft (15.2 m) or more is recommended to allow for variation in the GPS signal if WAAS is unavailable
(f) Press ENTER
to retain value.
(g) Press SYSTEM
12. Proceed to the Permanently Install GPS Tower Box section
23
INSTALLATION INSTRUCTIONS Install VRI-Zone Last Tower Box (Continued) Setup Control Panel for GPS Position TouchPro Control Panel v9.02 and Later Setup-Set Current Method To setup the GPS position type do the following at the control panel.
1. Set percent timer to 0.0% (zero percent)
2. Set water to Off
3. Press the Start button to start the machine, energize the safety circuit and the GPS pivot position tower box
4. The GPS pivot position tower box with GPS receiver is positioned near the collector ring and wired into either the control panel or collector ring.
5. Comm Port setup, press Main / Setup / Comm Port / Comm Port Tab.
(a) Select the Y-DB9 field and choose PLC from the drop-down list. See Figure 23-1.
(b) Select the Baud Rate field and choose 4800 bps from the drop-down list.
(c) Push the PLC tab.
(d) Check the GPSV2 checkbox. See Figure 23-2.
(e) Enter the PLC ID for the GPS tower box.
6. Check for satellite DGPS lock and satellite count.
(a) Push Main / Setup / Constants / Position Tab to see if the GPS receiver is locked on the DGPS satellite signal. If it is not locked on DGPS continue waiting. Depending on location it can take 15 minutes or longer for the GPS receiver to lock on to the satellite signal and obtain DGPS accuracy. If GPS position is not working see the Troubleshooting section.
7. After GPS receiver is locked on satellite signal, set current Pivot Point position.
(a) Push the Arrow next to Current GPS Position, then push Enter to set the Pivot Point position to the current position.
(b) Record the Pivot Point GPS Latitude and Longitude on the inside of control panel door.
8. Set the Distance to GPS (The distance from pivot point to GPS tower box).
(a) Select the Length to GPS (ft) field and enter the length from the pivot point to the GPS receiver. Do not enter the pivot length. The default is 1320 ft (402.3 m), and the range is 10 to 6554 ft (3.0 to 1997.6 m).
(b) Select the Plus Tolerance field and enter the Plus Tolerance for the length from pivot point to GPS receiver. The Default is 50 ft (15.2 m) and the range is 10 to 6554 ft (3.0 to 1997.6 m). A setting of 50 ft (15.2 m) or more is recommended to allow for variation in the GPS signal if Wide Area Application Services (WAAS) is unavailable.
(c) Select the Minus Tolerance field and enter the Minus tolerance for the length from pivot point to GPS receiver. The Default is 50 ft (15.2 m) and the range is 10 to 6554 ft (3.0 to 1997.6 m). A setting of 50 ft (15.2 m) or more is recommended to allow for variation in the GPS signal if WAAS is unavailable.
9. Set the Fallback Position Run Time.
(a) Select the Position Calculation Mode field and choose Runtime from the drop-down menu. The default is Runtime. Resolver is not recommended.
(b) Select the Pivot Speed field
(c) Enter pivot speed. The default is 15.56 ft/min (4.732 m/min).
(d) Push Enter .
(e) Select the Pivot Length field.
(f) Enter pivot length. The default is he default is 1320 ft (402.3 m).
(g) Push Enter .
(h) Push MainJ to go back to the status screen.
10. Proceed to the Permanently Install GPS Tower Box section
24
Permanently Install Tower Box
! DANGER • THE CONTROL PANEL, COLLECTOR RING AND TOWER BOXES CONTAIN HIGH VOLTAGE! 480 VOLTS CAN KILL.
1. SHUT OFF and LOCK the public power service disconnect to the irrigation machine. FILL OUT the blue (OSHA safety color code) tag and attach to the disconnect after locking. See figure 25-1.
2. SHUT OFF and LOCK the control panel main power disconnect. FILL OUT the blue (OSHA safety color code) tag and attach to the disconnect after locking. See figure 25-2.
OFF
ON
1
2
26
Disconnect Tower Box
! CAUTION • ALWAYS IDENTIFY POTENTIAL FALL HAZ- ARDS AND DETERMINE IF FALL PROTEC- TION EQUIPMENT IS APPROPRIATE FOR THE TASK, BEFORE BEGINNING THE WORK.
1. Take the tower box down from the temporary position near the collector ring. See figure 26-1.
2. Disconnect the temporary tower box wiring from the control panel or collector ring and tower box.
Install Tower Box 1. The VRI last tower box typically mounted on the
last span over the last regular drive unit.
Mount the tower box on one of the four drive unit mounting brackets using one control box mounting plate and four 5/16 x 1 cap screws and lock nuts. See figure 26-2.
On a machine with a corner, make sure the variable rate tower box does not interfere with the corner or any linkage.
2. Continue with Install VRI Intermediate Tower Boxes on the next page.
2 1
2
5
1
5
Figure 26-2 1. VRI Last Tower Box 2. DU Mounting Bracket 3. CB Mounting Bracket
4. 5/16 x 1 Screw 5. 5/16 Lock Nut
27
INSTALLATION INSTRUCTIONS Install VRI Intermediate Tower Boxes
! DANGER • THE CONTROL PANEL CONTAINS HIGH VOLTAGE! LIVE VOLTAGE CAN KILL.
1. SHUT OFF and LOCK the public power service disconnect to the irrigation machine. FILL OUT the blue (OSHA safety color code) tag and attach to the disconnect after locking. See figure 27-1.
2. SHUT OFF the control panel main power disconnect and open the control panel inner door. See figure 27-2.
3. Continue with Install Tower Boxes on the next page.
OFF
ON
1
2
28
INSTALLATION INSTRUCTIONS Install VRI Intermediate Tower Boxes (Continued) Install Tower Boxes Install the variable rate intermediate and last tower boxes. Two tower box mounting methods are shown below choose the tower box mounting method based on the application.
• Variable rate tower boxes should be mounted close to a drive unit for easy access.
• When GPS position is installed the last variable rate tower box should be mounted near the GPS receiver on last regular drive unit.
Bracket Mounting 1. Mount the variable rate tower box on one of the
four drive unit mounting brackets using one control box mounting plate and four 5/16 x 1 cap screws and lock nuts. See figure 28-1.
On a machine with a mechanical corner, make sure the variable rate tower box does not interfere with the corner or any linkage.
2. Continue with Set Tower Box Dip Switches on the next page.
Span Pipe Mounting 1. Mount up to two variable rate tower boxes on
span pipe near the drive unit using four half clamps. Secure tower boxes and half clamps to span pipe with four 1/2 x 2-1/2 cap screws and lock nuts. See figures 28-2 and 28-3.
NOTE • Make sure that the variable rate tower box and/or mounting does not interfere with intermediate tower box linkage or mechanical corner run cycle box linkage.
2. Continue with Set Tower Box Sync Pattern Dip Switches on the next page.
2
5
1
5
Figure 28-1 1. Variable Rate Tower Box 2. DU Mounting Bracket 3. CB Mounting Bracket
4. 5/16 x 1 Screw 5. 5/16 Lock Nut
2
5
1
4
3
3
4
5
Single Tower Box Span Pipe Mounting Shown
Figure 28-2 1. Variable Rate Tower Box 2. Span Pipe 3. Half Clamp
4. 1/2 x 2-1/2 Screw 5. 1/2 Lock Nut
2
5
1
4
3
3
4
5
1
Double Tower Box Span Pipe Mounting Shown
Figure 28-3 1. Variable Rate Tower Box 2. Span Pipe 3. Half Clamp
4. 1/2 x 2-1/2 Screw 5. 1/2 Lock Nut
29
INSTALLATION INSTRUCTIONS Install VRI Intermediate Tower Boxes (Continued) Set Tower Box Sync Pattern Dip Switches 1. Set the sync pattern dip switches number 5, 6,
7 and 8 to the same sync pattern as the control panel power line carrier. See figure 29-1.
• All circuit boards on one individual machine must use the same sync pattern. See figure 29-1.
NOTE • When using Version 1 modem card with the Version 2 modem card on the same system take note of the following:
• The Version 1 modem card cannot communicate with the Version 2 modem card when dip switch synchronization settings 5 through 16 are used. See figure 29-1.
2. Continue with Set Tower Box ID Dip Switches on the next page.
Version 2 Modem
Figure 29-1 Power Line Carrier Dip Switch Sync Pattern Settings
30
INSTALLATION INSTRUCTIONS Install VRI Intermediate Tower Boxes (Continued) Set Tower Box ID Dip Switches 1. Set the dip switch I.D. number for each variable
rate tower box. Up to 15 variable rate tower boxes can be identified. See figures 30-1 and 30-2.
(a) The 1st tower box is the one closest to the pivot point. Other tower boxes that are farther away from the pivot point are identified in nu- merical order beginning with 2nd tower box. See figures 30-1 and 30-2.
(b) Set the dip switch on each variable rate tower box circuit board with a different I.D. number. See figure 30-1.
(c) Use a permanent marker to write the tower box ID on the outside of tower box cover
2. Continue with Identify Sprinkler Bank Solenoids on the next page.
1ST TOWER BOXI.D. NUMBERS
Figure 30-1 PLC Tower Box ID Number Dip Switch Settings
Pivot
LRDU
Pivot
LRDU
1
1
2
Figure 30-2 Single PLC Tower Box Span Pipe Mounting Shown 1. 1st Tower Box (Closest to Pivot Point)
Double PLC Tower Box Span Pipe Mounting Shown 1. 1st Tower Box (Closest to Pivot Point) 2. 2nd Tower Box
31
INSTALLATION INSTRUCTIONS Install VRI Intermediate Tower Boxes (Continued) Identify Sprinkler Bank Solenoids 1. Identify and mark the sprinkler bank solenoids on
each variable rate tower box. See figures 31-1 and 31-2.
2. Continue with Install Sprinkler Valves instruction below.
Install Sprinkler Valves 1. Install sprinkler valve plumbing with pipe sealant
in locations on span pipe as required for the application. See figure 31-2.
2. Refer to the sprinkler chart for this application and mark each sprinkler valve with #1 or #2 to indicate which solenoid valve it will connect to.
3. A typical sprinkler valve plumbing configuration is shown in figure 31-2.
However, the sprinkler valve plumbing configuration may vary depending on application.
• This configuration with the sprinkler valve installed horizontally allows water to drain away from the valve in either direction to prevent damage due to freezing conditions. Other configurations are shown in the parts section of this manual.
4. The water filter and stand pipe are optional.
• If the water filter will be installed see Install Water Filter instruction below.
• If the stand pipe will be installed see Install Stand Pipe instruction on the next page.
• If nether the water filter or the stand pipe will be installed proceed to Install Sprinkler Bank Tubing Harnesses on page 33.
Install Water Filter (Optional) 1. Assemble water filter plumbing as shown in fig-
ure 31-3.
2. Install water filter plumbing in any sprinkler fitting on span pipe near the variable rate tower box. See figure 31-3.
3. Route a length of plastic tubing from the water filter fitting to T fitting in port #1 or P on solenoid #2 of the variable rate tower box. See figure 31-3.
4. Secure plastic tubing with plastic wire ties as needed.
5. Repeat Steps 1 through 5 for each water filter/ variable rate tower box.
6. Continue with Install Sprinkler Bank Tubing Har- nesses instruction on page 33.
Sol #1 Sol #2
Figure 31-2 Typical Sprinkler Valve Configuration
Sol #2 Port 1 or P
1
2
3
4
5
67
9
10
11
8
Figure 31-3 1. 3/4 x 2 Nipple 2. 3/4 Tee 3. 3/4 x 90 Street Elbow 4. 3/4 x 2 Nipple PVC 5. Water Filter 6. 3/4 Pipe Bushing PVC
7. 1/4 Pipe Bushing 8. Elbow Tube Fitting 9. 3/4 x 6 Nipple 10. 3/4 Coupler 11. Plastic Tubing
32
INSTALLATION INSTRUCTIONS Install Stand Pipe (Optional) The Stand Pipe Option is used to reduce OFF duty cycle lag time in extreme applications where it takes more than a few seconds for sprinkler valves in a specific zone to close. See figure 32-1.
This option is typically not used in normal applications.
1. Assemble stand pipe plumping as shown in figure 32-1.
2. Do one of the following.
• Attach stand pipe assembly to span pipe flange with two 1/2 x 2-1/2 cap screws, flat washers and lock nuts. See figure 32-1.
or
• Attach stand pipe assembly to half clamp mount with two 1/2 x 2-1/2 cap screws, four flat washers and two lock nuts.
• 5, 6-5/8, 8-5/8 Span Pipe
» Attach half clamp and half clamp mount to span pipe to span pipe with two 1/2 x 2-1/2 cap screws and lock nuts.
• 6 or 8 Span Pipe
» Attach half clamp and half clamp mount to span pipe to span pipe with two 1/2 x 2-1/2 cap screws, spacers and lock nuts.
• 10 Span Pipe
» Attach half clamp and half clamp mount to span pipe to span pipe with two 5/8 x 2-1/2 cap screws and lock nuts to secure on When the span pipe is 10 inches . See figure 32-1.
3. Route a length of plastic tubing from exhaust port fitting on each solenoid valve to one of the fittings on stand pipe. See figure 32-2.
4. Secure each connection with crimp clamp.
5. Secure plastic tubing with plastic wire ties as needed.
6. Make sure the stand pipe ball valve is closed during operation. See figure 32-2
7. Repeat Steps 1, through 6 for each stand pipe/ variable rate tower box.
8. Continue with Install Sprinkler Bank Tubing Har- nesses on the next page.
1
2
3
1
2
5
83
1212
14
Figure 32-1 1. Running Light Bracket 2. 3/4 x 3/4 Cross Fitting 3. 3/4 Ball Valve 4. 3/4 Elbow 5. 3/4 to 1/8 Reducer 6. Elbow 1/8 x 1/4 Hose Barb 7. 3 Plastic Tubing 8. 1/8 x 1/4 Hose Barb Fitting 9. 1/2 X 2-1/2 Cap Screw
10. 1/2 Flat Washer 11. 1/2 Lock Nut 12. Half Clamp Mount 13. Half Clamp 14. Spacer (as Required)
Stand Pipe Span Pipe Mounting Shown
1
Figure 32-2 1. Plastic Tubing 2. Exhaust Port 3. Solenoid
4. Fitting 5. Stand Pipe 6. Ball Valve
33
INSTALLATION INSTRUCTIONS Install Sprinkler Bank Tubing Harnesses 1. Route a length of plastic tubing from the fitting
on port A or #2 on sprinkler bank #1 solenoid valve #1 down span pipe, under existing span cable clamps to the fitting on last sprinkler valve that will connect to solenoid valve #1. This is the sprinkler bank #1 solenoid #1 tubing harness. See figure 33-1.
2. Use a Tee fitting and short length of plastic tubing to connect each required sprinkler valve to the sprinkler bank #1 solenoid #1 tubing harness. See figure 33-2.
3. Secure each connection with crimp clamp. See figure 33-2.
4. Route a length of plastic tubing from the fitting on port A or #2 on sprinkler bank #1 solenoid valve #1 down span pipe, under existing span cable clamps to the fitting on last sprinkler valve that will connect to solenoid valve #2. This is the sprinkler bank #1 solenoid #2 tubing harness. See figure 33-1.
5. Use a Tee fitting and short length of plastic tubing to connect each required sprinkler valve to the sprinkler bank #1 solenoid #2 tubing harness. See figure 33-2.
6. Secure each valve/tube connection with crimp clamp. See figure 33-2.
7. Repeat Steps 1 through 6 for each sprinkler bank.
8. Continue with Install Strain Relief Fittings instruction on the next page.
Sol #2 Port A or #2
1
2
3
3
Figure 33-1 1. Solenoid #1 Tubing Harness 2. Solenoid #2 Tubing Harness 3. Crimp Clamp
1 2
4
3
Figure 33-2 1. Plastic Tubing 2. Sprinkler Valve 3. Tee Fitting 4. Crimp Clamp
34
INSTALLATION INSTRUCTIONS Install Strain Relief Fittings 1. Install strain relief fitting in each variable rate
tower box and secure with one lock nut. See figure 34-1.
2. Install strain relief fitting in each existing tower box as required and secure with one lock nut. See figure 34-1.
3. Continue with Wire Variable Rate Tower Boxes instruction below.
Wire Variable Rate Tower Boxes 1. Refer to the field install and wiring diagrams sec-
tion and wire the variable rate tower boxes to the existing tower boxes.
2. After the wiring is completed continue with one of the set up procedures listed below:
Pro2 Control Panel v8.40 and higher, Setup Variable Rate Irrigation Zone Option....................................51
TouchPro Control v9.02 and higher, Setup Variable Rate Irrigation Zone Option....................................52
2
1
3
6
1
3
Figure 34-1 1. Strain Relief Fitting 2. Variable Rate Tower Box 3. Lock Nut 4. Existing Tower Box
35
FIELD INSTALL AND WIRING DIAGRAMS
Contents Decal Dip Switch Settings for Power Line Carrier pn 0998384............................................................................................... 36 Field Install Dip Switch Settings pn 9311996 ......................................................................................................................... 37 Field Wiring VRI Intermediate Tower Box pn 9311842 ........................................................................................................... 38 Decal Wiring Schematic VRI Intermediate Tower Box pn 0998385 ........................................................................................ 39 Field Install Stand Pipe Option pn 9311843 ........................................................................................................................... 40 Field Install Data Port Programming Cable pn 9311846 ........................................................................................................ 41
5 Volt communications Pro2 Field Wiring Power Line Carrier 5 Volt Comm Signal to Control Panel pn 9311777 ................................................ 42 TouchPro v9.02 Field Wiring Power Line Carrier 5 Volt Comm Signal to Control Panel pn 9311856_D .......................... 43 Field Wiring VRI 5 Volt Communications Signal Last Tower Box pn 9311844 .................................................................. 44 Decal Wiring Schematic VRI 5 Volt Communications Signal Last Tower Box pn 0998386............................................... 45
15 Volt Communications Pro2 Field Wiring Power Line Carrier 15 Volt Comm Signal to Control Panel pn 9311829 .............................................. 46 TouchPro v9.02 Field Wiring Power Line Carrier 15 Volt Comm Signal to Control Panel pn 9311859_C ........................ 47 Field Wiring VRI 15 Volt Communications Signal Last Tower Box pn 9311845 ................................................................ 48 Decal Wiring Schematic VRI 15 Volt Communications Signal Last Tower Box pn 0998387............................................. 49
36
FIELD INSTALL AND WIRING DIAGRAMS Decal Dip Switch Settings for Power Line Carrier pn 0998384
37
FIELD INSTALL AND WIRING DIAGRAMS Field Install Dip Switch Settings pn 9311996
38
FIELD INSTALL AND WIRING DIAGRAMS Field Wiring VRI Intermediate Tower Box pn 9311842
39
FIELD INSTALL AND WIRING DIAGRAMS Decal Wiring Schematic VRI Intermediate Tower Box pn 0998385
40
FIELD INSTALL AND WIRING DIAGRAMS Field Install Stand Pipe Option pn 9311843
41
FIELD INSTALL AND WIRING DIAGRAMS Field Install Data Port Programming Cable pn 9311846
42
FIELD INSTALL AND WIRING DIAGRAMS Pro2 Field Wiring Power Line Carrier 5 Volt Communications Signal To Control Panel pn 9311777
5 Volt communications Pro2 Field Wiring Power Line Carrier 5 Volt Comm Signal to Control Panel pn 9311777
43
FIELD INSTALL AND WIRING DIAGRAMS TouchPro v9.02 Field Wiring Power Line Carrier 5 Volt Comm Signal to Control Panel pn 9311856_D
44
FIELD INSTALL AND WIRING DIAGRAMS Field Wiring VRI 5 Volt Communications Signal Last Tower Box pn 9311844
45
FIELD INSTALL AND WIRING DIAGRAMS Decal Wiring Schematic VRI 5 Volt Communications Signal Last Tower Box pn 0998386
46
FIELD INSTALL AND WIRING DIAGRAMS Pro2 Field Wiring Power Line Carrier 15 Volt Communications Signal to Control Panel pn 9311829
15 Volt Communications Pro2 Field Wiring Power Line Carrier 15 Volt Comm Signal to Control Panel pn 9311829
47
FIELD INSTALL AND WIRING DIAGRAMS TouchPro v9.02 Field Wiring Power Line Carrier 15 Volt Comm Signal to Control Panel pn 9311859_C
48
FIELD INSTALL AND WIRING DIAGRAMS Field Wiring VRI 15 Volt Communications Signal Last Tower Box pn 9311845
49
FIELD INSTALL AND WIRING DIAGRAMS Decal Wiring Schematic VRI 15 Volt Communications Signal Last Tower Box pn 0998387
50
Setup
Setup Variable Rate Irrigation Zone Option Pro2 8.40 or Higher To setup the Variable Rate Irrigation Option (VRI-Zone) with GPS Position the GPS position option must be setup first.
» If the GPS position option was setup using the Setup Control Panel for GPS Position instructions in the Install VRI-Zone Last Tower Box section of this manual, continue with step 1 below.
» If the GPS position option has not been setup, go back to the Install VRI-Zone Last Tower Box section of this manual and perform the necessary GPS position installation procedures before continuing.
• Determine the minimum flow rate. The minimum flow rate is determined by the pump curve and hydraulics of the center pivot.
• Determine the maximum pressure setting. The maximum pressure setting is determined by the pump curve and hydraulics of the center pivot. If there is an underground pipeline it is recommended that the setting be 10% below the pressure rating of the pipeline. Contact the pump supplier for guidance.
1. Set the Protocol for the 9-pin and 25 pin com ports.
(a) Press SYSTEM , 1 , 8 , 8 , 7 and 1 (9-pin com port).
(b) Press 1 and 5 for REMOTE CTL protocol. Used to down load variable rate prescription plans.
(c) Press 2 and 5 for 9600 baud.
(d) Press ESC to go back to the com port screen.
(e) Press 2 (25-pin com port).
(f) Press 1 , 3 , and 3 to enable VRI Zone Control.
(g) Press ESC and ESC .
(h) Press 2 and 4 for 4800 baud rate.
(i) Press SYSTEM to go back to the status screen. 2. Set the Constants for VRI Zone Control.
(a) Press SYSTEM , 1 , 8 , 8 , 8 and 5 for the VRI Zone Control screen. • If a flow meter will be used in this application continue with step b. • If a flow meter will not be used in this application continue with step c.
(b) Press 2 for minimum flow rate screen (min flow rate). The current setting is shown ( ) in gpm (lps).
(i) Enter the minimum flow rate value for this application and press ENTER
. The range is 1-999 gpm (lps).
(c) Press 3 for maximum pressure screen (max pres). The current setting is shown ( ) in psi (kPa).
(i) Enter the maximum pressure value for this application and press ENTER
. The range is 1-999 psi (kPa).
(d) Press 4 for valve resync. The current setting is shown ( ) in psi (kPa).
(i) Enter the resync pressure value for this application and press ENTER
. Typically set 5 psi (34.4 kPa) below the maximum pressure setting. The range is 1-999 psi (kPa).
(e) Press 5 for sprinkler banks. The current setting is shown ( ).
(i) Enter the number of sprinkler zones for this application and press ENTER
. Range is 1-30 sprinkler zones.
(ii) Press SYSTEM to go back to the status screen. 3. Turn on the VRI Zone Control feature
(a) Press OPTION , 8 , 7 , 1 and 1 to turn VRI Zone Control ON.
(b) Press SYSTEM to go back to the status screen. 4. Control panel setup for Variable Rate Irrigation Option is complete. Continue with Test and Adjust GPS
Position on page 53.
51
SETUP
Setup Variable Rate Irrigation Zone Option - TouchPro v9.02 or Higher To setup the Variable Rate Irrigation Option (VRI-Zone) with GPS Position the GPS position option must be setup first.
» If the GPS position option was setup using the Setup Control Panel for GPS Position instructions in the Install VRI-Zone Last Tower Box section of this manual, continue with step 1 below.
» If the GPS position option has not been setup, go back to the Install VRI-Zone Last Tower Box section of this manual and perform the necessary GPS position installation procedures before continuing.
• Determine the minimum flow rate. The minimum flow rate is determined by the pump curve and hydraulics of the center pivot.
• Determine the maximum pressure setting. The maximum pressure setting is determined by the pump curve and hydraulics of the center pivot. If there is an underground pipeline it is recommended that the setting be 10% below the pressure rating of the pipeline. Contact the pump supplier for guidance.
1. Set the Protocol for the com ports. (a) Comm Port setup, press Main / Setup / Comm Port / Comm Port Tab. (b) Select the DB9 field and choose Remote Control from the drop-down list. Used to down load variable
rate prescription plans. (c) Select the Baud Rate field and choose 9600 bps from the drop-down list.
(d) Push the PLC tab.
(e) Check the VRi-Zone checkbox to enable VRI Zone Control. 2. Set the Constants for VRI Zone Control.
(a) Push Options / VRI / VRI-Z Constants to display the VRI-Z Constants screen. • If a flow meter will be used in this application continue with step b. • If a flow meter will not be used in this application continue with step c.
(b) The Min Flow Rate field displays the current minimum flow rate in gpm (lpm). To change the minimum flow rate, select the Min Flow Rate field and enter the new minimum flow rate value. The range is 1-999 gpm ( lpm). Push Enter to retain the value.
(c) The Maximum Pressure (Max Pressure) field displays the current maximum pressure in psi (kPa). To change the maximum pressure limit, select the Max Pressure field.Enter the new maximum pressure value. The range is 1-999 psi (kPa). The default is 80 psi (551.5 kPa). Push Enter to retain the value.
(d) The Valve Resync Pressure field displays the current resync pressure in psi (kPa). To change the valve resync pressure, select the Valve Resync Pressure field. Enter a new resync pressure value. The range is 1-999 psi (6.90-6887.90 kPa). The default is 60 psi (413.7 kPa). Push Enter to retain the value.
(e) The # of Sprinkler Banks field displays the current number of sprinkler banks. To change the number of sprinkler banks, select the # of Sprinkler Banks field and choose the number of sprinkler banks for this application. The range is 1-30 sprinkler zones. The default is 1.
3. Push Options, VRI, VRI-Z Map to display the VRI-Z Map screen. Select the VRI-Z field. Choose ON to turn VRI-Z on, or choose OFF to turn VRI-Z off.
4. Control panel setup for Variable Rate Irrigation Option is complete. Continue with Test and Adjust GPS Position on page 55.
52
SETUP
53
TESTING Test and Adjust GPS Position - Pro2 Use the following procedure to view the position screen of a Pro2 control panel and verify that the GPS position sensor is working and then set the pivot position.
NOTE • Initially it may be necessary to run the machines in both directions so that the positon displayed on the screen is accurate.
• When the direction of travel changes the position is updated with the GPS position.
1. View the Position screen. See figure 53-1.
a) Press SYSTEM
• Current Position: The unfiltered and filtered GPS positions are displayed.
• Sat Count: Displays the number of satellites in view.
• Lock: Displays the satellite signal (None, Stan- dard or DGPS) that the GPS receiver is locked on.
• Lat: Displays the current latitude.
• Lon: Displays the current longitude.
• Current Position: Displays the current position
of the machine.
3. Run machine in either direction to verify that the position displayed on the status screen changes periodically as the machine moves.
• If GPS position is not working see the Trouble- shooting section.
• If GPS position is workingcontinue with step 4.
4. If 0 degrees north is not desired set the position of the pivot span in degrees. Position value is located on Position screen. Must have GPS Lock in order to edit position. Default is 0 degrees, machine pointing north.
(a) Press SYSTEM
(c) Press ENTER
to retain value.
5. Press SYSTEM
to go back to the status screen.
6. Installation of the GPS position option for variable rate irrigation is complete. Continue with Test Variable Rate Irrigation on the next page.
CURRENT POSITION: 288.3 -> 175.6 SAT COUNT: 8 LOCK: DGPS LAT: (-30.297895) LON: (-127.739125) CURRENT POSITION (175.6) >
Figure 53-1
54
TESTING
0 EXIT 1 RESYNC VALVES 2 TEST VALVES PRESS NUMBER > 2
Figure 54-2
0 EXIT 3 CRUISE CTL 6 N/A 1 SYS FAULTS 4 VRI-Z DIAG 7 NA 2 ERROR LOG 5 PLC ERRORS PRESS NUMBER > 4
Figure 54-1
Test Variable Rate Irrigation - Pro2 Use the following procedure to test the operation of the variable rate irrigation sprinkler banks.
1. Set the percent timer above 0.0 (zero percent), start the machine, turn water on and with the machine running, do the following to verify that each sprinkler bank is working.
2. Use the diagnostics test valves feature.
(a) Press DIAGNOSTICS
, 4 and 2 for Test Valves screen. See figures 54-1 and 54-2.
(b) Enter the sprinkler bank valve number to test. See figure 54-3.
(c) Press ENTER
to turn valve OFF.
• Example: Press 30 and ENTER to turn sprinkler bank valve 30 OFF.
• This feature will turn all sprinkler bank valves on (1=ON) and then turn the valve number entered to off (0=OFF). This setting will be maintained for 5 minutes or until a different sprinkler bank is commanded off. After 5 minutes the control panel resorts back to the programmed settings.
3. Repeat steps (b) and (c) for all sprinkler bank valves.
• If the sprinkler banks work correctly installation is complete.
• If the sprinkler banks do not work correctly, verify proper installation of VRI tower boxes and dip switch settings. See Troubleshooting section.
TURNS ONE VALVE OFF FOR FIVE MINUTES 1-10 11-20 21-30 XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
PRESS NUMBER OF VALVE TO TURN OFF > Figure 54-3
Test Variable Rate Irrigation
55
TESTING Test and Adjust GPS Position - TouchPro If the machine is equipped with GPS Position, do the following to verify that GPS Position is working.
1. Push Setup, Constants, Position to display the Position settings. Refer to Figure 55-1.
2. When GPS Position is working, the Position screen displays the fields listed below. See Figure 55-1.
• Current GPS Position:
» Count – the number of satellites in view
» Sat Lock – the satellite signal (None, Standard, DGPS, and No GPS) onto which the GPS receiver is locked
» Lat – the current latitude
» Lon – the current longitude
• Pivot Point GPS Position – the current position (latitude and longitude) of the machine's pivot point
• In Event of GPS Signal Loss:
» Shutdown System – a position loss function that shuts the system down
» Disable Endguns – a position loss function that disables the endguns
» Fallback Position – a position loss function that calculates the position until the GPS position is re-acquired
» Pivot Speed – the pivot's current speed (ft/min)
» Pivot Length – the pivot's current length (ft)
When the GPS Position is lost No GPS is displayed in the Sat Lock field.
3. Run the machine in either direction to verify that the position displayed on the Status screen changes periodically as the machine moves.
• If GPS position is not working, refer to the Troubleshooting section of this manual or call your local Valley Dealer.
• If GPS position is working, the installation is complete.
4. If 0 degrees north is not desired set the position of the pivot span in degrees. Position value is located on Position screen. Must have GPS Lock in order to edit position. Default is 0 degrees, machine pointing north. See Figure 55-2.
(a) Push Calibrate.
(b) Using the numeric keypad, enter the current pivot position from 0.0° to 359.9°.
(c) Push Enter .
5. Installation of the GPS position option for variable rate irrigation is complete. Continue with Test Variable Rate Irrigation on the next page.
2
5
1
43
Figure 55-1 1. Current Position 2. Pivot Point GPS 3. Sat Lock 4. Count 5. In Event of GPS Signal Loss
TouchPro Test and Adjust GPS Position
1
56
TESTING Test Variable Rate Irrigation - TouchPro Use the following procedure to test the operation of the variable rate irrigation sprinkler banks.
1. Set the percent timer above 0.0 (zero percent), start the machine, turn water on and with

installation manual 5 volt or 15 volt communication signal

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