GILTRAP GENERATION II RF CONTROL SYSTEM

Transcription

1 GILTRAP GENERATION II RF CONTROL SYSTEM Operating, Installation & Technical Manual February 2010 Introduction... 2 Control Mode Options... 2 Remote Display Layout... 3 Controller Layout... 3 Operation Section...4 Overview... 4 Valve Over-ride Function... 4 REMOTE DISPLAY SCREENS... 5 Screen Symbols... 5 Start-up Screen... 5 Standard Mode Screen... 6 Weight Mode Screen... 7 Distance Mode Screen... 8 Speed Mode Screen... 9 Scales Screen Installation Section...11 Component Layout Remote Display Mounting & Power Supply Forage Wagon Controller & Power Supply Setting the RFID Number Fitting the Power Module Circuit Board Fitting the Wheel Sensor Fitting the Load Cells Setting System Parameters Checking Setup Parameters Factory Parameter Settings Final Check Technical Section...24 Power and Charging System Display LEDs System Safety Fuses Radio Frequency Device Wiring Schematic Cable Descriptions Remote Display Screen Contrast Fault Diagnosis... 31

2 2 Introduction The Giltrap Generation II RF Control System consists of a Controller that is mounted on the wagon that uses wireless technology to relay data such as feed rate, load weights or feedout amounts (depending on options purchased) from the wagon and displays it on the Remote Display mounted near the operator on the tractor, allowing the operator to control the feed rate using different modes. Powerfully capable, yet simple to use, the controller has large buttons and an easy-to-read display allowing the operator to constantly monitor, and adjust the feed rate when needed, all while on the move. Control Mode Options The system has a total of five different operation modes available. The availability of these are dependant on the hardware options fitted to the machine. Hardware available: Load cells for weight readings Solenoid coil for floor control Wheel sensor for ground speed calculation Standard Mode The operator controls the feed rate through a percentage range from 0 to 100%. Requires a solenoid coil to be fitted. Load cells are optional. Weight Mode The operator can enter a target weight to feed. The feed rate control is the same as Standard mode. Requires load cells and solenoid coil to be fitted. Distance Mode (also known as Fully Automatic mode) The wagon will unload the required amount over the required distance, and will compensate for changes in ground speed. Requires load cells, solenoid coil and wheel sensor to be fitted. Speed Mode The operator controls the feed out rate through a percentage range from 0 to 100% and the feed rate is automatically adjusted according to ground speed. Requires a solenoid coil and wheel sensor to be fitted. Load cells are optional. Scales Mode Only has a weight display. Requires load cells to be fitted. Floor rate is controlled manually.

3 3 Remote Display Layout Display screen UP button Power switch GO button TARE/GROSS button STOP button LEFT button RIGHT button ZERO button MODE button DOWN button Power plug Controller Layout Power ON button Power light Signal light Power OFF button Signal light Valve light Weight connection Valve connection Power connection

4 4 Operation Section Overview Assuming installation (page 11 23) has been completed, the power for the system is controlled by the switch adjacent to the Remote Display. 1. Turn the switch on to provide power to the Remote Display and the wagon. 2. If the wagon is disconnected, press and hold the ON button on the Controller for one second. The Controller is now operating on its own battery. 3. Begin loading the wagon. See more detailed information regarding modes and buttons. 4. Once completed loading, connect the wagon to the tractor and connect the 7-pin plug. 5. Once ready to feed, select the appropriate mode and press GO button. You are now ready to proceed. Note: The Controller power light will illuminate when the ON button is pressed or the wagon is plugged into the tractor. To turn off, the wagon must be un-plugged before pressing the OFF button. Valve Over-ride Function When a solenoid is fitted for floor control, a manual over-ride function will also be provided. Note: This function over-rides all RF floor rate control. Use ¼ - ½ turn adjustments per time. Do not over-adjust. For electronic operation with RF control, the screw adjuster must be unscrewed all the way out (anti-clockwise) and the locking ring tightened. Locking ring IMPORTANT Manual over-ride located beneath this cover Over-ride adjuster To operate in case of electronic malfunction, undo locking ring and screw in adjuster. Use ¼ - ½ turn adjustments. Label on cover

5 5 Remote Display Screens Screen Symbols Apart from usual text characters, the screen can display other symbols at various times. The battery symbol indicates when the system is operating on its own battery. The voltage display indicates the condition of the battery. The antenna symbol indicates when the Controller and Remote Display have communication between them. This must show at all times for successful operation. Start-up Screen When the Remote Display is powered up, the start-up screen is displayed for 3 seconds as below. After this the screen will change to the operating screen. GILTRAP GEN II CONTROL SYSTEM Remote Display RF channel Channel: Rev Remote Display software revision If the wagon is not connected i.e. not getting power from the tractor, the controller will not start. The screen below will display until communication has begun by plugging in the wagon or pressing and holding the GO button on the controller for 1 or more seconds. After establishing communication, it will proceed directly to the next screen. Waiting for RF Forage Wagon Communications... Once communication has begun between the devices, a screen similar to the one below will show. FEED RATE: DISPENSED: GROSS: STOP Std 50% 0kg 2950kg 12.5V The modes that are available are dependant on the hardware options fitted to the machine.

6 6 Standard Mode Screen In standard mode, the feed rate is shown as a percentage. A range of 1-100% is available with 100% being maximum feed rate. This rate is shown on the top line of the screen. This mode is useful for general operation and is the most simple to use. FEED RATE: 50% Feed Rate System status Rate control only Mode of operation STOP Rate control with load cells fitted Std FEED RATE: DISPENSED: GROSS: STOP Std Connectivity status 50% 1050kg 2950kg 12.5V Dispensed amount Product amount in machine Battery voltage System battery indicator Screen Features: The top line shows the feed rate. The bottom line of the screen shows the status of the system (STOP), the mode of operation (Std) and connectivity status. Additional features that show if load cells are fitted: The second line will show the weight dispensed since GO was pressed. The third line will display the present wagon weight. This may be gross or tare. The bottom line of the screen shows the status of the system (STOP), the mode of operation (Std), the battery voltage (highest voltage available to the unit. When disconnected from the tractor, this will be the internal battery voltage), and connectivity status. Operating Notes: The operator can adjust the rate percentage figure by pressing UP or DOWN on the keypad. The operator can select between gross and tare weight to be displayed by pressing TARE/GROSS on the keypad. The operator can zero only the dispensed weight by pressing GO on the keypad. The operator can start and stop the feed-out by pressing GO and STOP on the keypad. The operator can switch to other available operating modes by pressing MODE on the keypad. The operator can zero the gross and dispensed weight by pressing ZERO on the keypad. Screen Warnings: WAGON POWER NOT CONNECTED will flash on the display if the GO button on the Remote Display is pressed without the wagon being plugged into the tractor and/or power not getting from the tractor to the Controller.

7 7 Weight Mode Screen In Weight mode, the feed rate is shown as a percentage. A range of 1-100% is available with 100% being maximum feed rate. This rate is shown on the top line of the screen. The operator can enter a target weight to feed out before the wagon floor will stop moving and the system status will return to STOP. (V3.9 onwards) The operator can enter a target weight to feed out before a beeper will sound and the wagon floor will stop moving and the system status will return to STOP. (All) The TO FEED value must be greater than zero else the system will not operate. Use STANDARD mode for feeding if weight quantities are required. Mode of operation System status System battery indicator FEED RATE: TO FEED: GROSS: STOP Weight 50% 560kg 2950kg 12.5V Feed Rate Target weight to feed Product weight in machine Connectivity status Battery voltage Screen Features: The top line shows the feed-out rate. The second line shows the weight to feed out before a beeper sounds. The third line shows the weight of the current load. This may be gross or tare. The bottom line of the screen shows the status of the system (STOP), the mode of operation (Weight), the battery voltage (highest voltage available to the unit. When disconnected from the tractor, this will be the internal battery voltage), and connectivity status. Operating Notes: The operator can alter the feed-out rate by adjusting the rate percentage by pressing UP or DOWN on the keypad. The operator can adjust the weight to be dispensed by adjusting the TO FEED figure. This is done by pressing UP or DOWN on the keypad when the TO FEED figure is underlined. Use the RIGHT or LEFT button to move the underline cursor. The operator can start and stop the feed-out by pressing GO and STOP on the keypad. The operator can switch to other available operating modes by pressing MODE on the keypad. The operator can select between gross and tare weight to be displayed by pressing TARE/GROSS on the keypad. The operator can zero the gross and dispensed weight by pressing ZERO on the keypad. Screen Warnings: WAGON POWER NOT CONNECTED will flash on the display if the GO button on the Remote Display is pressed without the wagon being plugged into the tractor and/or power not getting from the tractor to the Controller.

8 8 Distance Mode Screen In Distance mode, the feed rate is automatically set by dispensing feed over a set distance. Mode of operation System status TO FEED: LENGTH: GROSS: STOP Dist 1800kg 100m 2950kg 12.5V Feed to dispense Distance to travel Product weight in machine Connectivity status Battery voltage System battery indicator Screen Features: The top line shows the weight to feed out. The second line shows the distance over which to feed this weight. The third line shows the present wagon weight. This may be gross or tare. The bottom line of the screen shows the status of the system (STOP), the mode of operation (Dist), the battery voltage (highest voltage available to the unit. When disconnected from the tractor, this will be the internal battery voltage), and connectivity status. Operating Notes: The operator can adjust the weight to be dispensed by adjusting the TO FEED figure. This is done by pressing UP or DOWN on the keypad when the TO FEED figure is underlined. Use the RIGHT or LEFT button to move the underline cursor. The operator can adjust the distance to feed the weight over by adjusting the LENGTH figure. This is done by pressing UP or DOWN on the keypad when the LENGTH figure is underlined. Use the RIGHT or LEFT button to move the underline cursor. The operator can start or stop the operation by pressing GO or STOP on the keypad. If the feed bins are unequal in length, enter the total length of the bins in the LENGTH figure and the total amount to feed in the TO FEED figure. After travelling the first bin, press STOP on the keypad. The display will change from RUN to WAIT. You can then travel forward or backward without the distance changing. Press GO to continue or press and hold the STOP button for 3 or more seconds to reset the system status to STOP. The system will automatically return to STOP mode after counting down the distance to zero. The operator can switch to other available operating modes by pressing MODE on the keypad. The operator can select between gross and tare weight to be displayed by pressing TARE/GROSS on the keypad. The operator can zero the gross and dispensed weight by pressing ZERO on the keypad. Screen Warnings: WAGON POWER NOT CONNECTED will flash on the display if the GO button on the Remote Display is pressed without the wagon being plugged into the tractor and/or power not getting from the tractor to the Controller. INCREASE GROUND SPEED will flash on the display when the wagon is travelling too slow and causing the machine to overfeed. Note that ground speed needs to increase not tractor revs. DECREASE GROUND SPEED will flash on the display when the wagon is travelling faster than the machine can feed. Note that ground speed needs to decrease not tractor revs.

9 9 Speed Mode Screen In Speed mode, the machine will maintain a consistent feed-rate relative to ground speed. The feed rate percentage is adjustable from 1 100%. FEED RATE: 50% Feed Rate System status Rate control only Mode of operation STOP Speed Rate control and load cells fitted FEED RATE: DISPENSED: GROSS: STOP Speed Connectivity status 50% 940kg 3540kg 12.5V Dispensed amount Product weight in machine Battery voltage System battery indicator Screen Features: The top line shows the feed rate. The bottom line of the screen shows the status of the system (STOP), the mode of operation (Speed) and connectivity status. Additional features that show if load cells are fitted: The second line shows the weight fed out since the wagon was loaded. The third line shows the present wagon weight. This may be gross or tare. The bottom line of the screen shows the status of the system (STOP), the mode of operation (Speed), the battery voltage (highest voltage available to the unit. When disconnected from the tractor, this will be the internal battery voltage), and connectivity status. Operating Notes: The operator can alter the feed-out rate by adjusting the rate percentage by pressing UP or DOWN on the keypad while in STOP mode only. The operator can adjust the weight to be dispensed by adjusting the TO FEED figure. This is done by pressing UP or DOWN on the keypad when the TO FEED figure is underlined. Use the RIGHT or LEFT button to move the underline cursor. The operator can start or stop the feed-out by pressing GO or STOP on the keypad. The operator can zero only the dispensed weight by pressing GO on the keypad. The operator can switch to other available operating modes by pressing MODE on the keypad. The operator can select between gross and tare weight to be displayed by pressing TARE/GROSS on the keypad. The operator can zero the gross and dispensed weight by pressing ZERO on the keypad. Screen Warnings: WAGON POWER NOT CONNECTED will display if the GO button on the Remote Display is pressed without the wagon being plugged into the tractor and/or power not getting from the tractor to the Controller.

10 10 Scales Screen In Scales mode, the screen will only display weight figures. This mode is used when no rate control is fitted to the wagon. No other modes are available if only load cells are fitted. The operator can enter a target weight to feed when a beeper will sound, the wagon floor will stop moving (if the floor control solenoid is fitted) and the system status will return to STOP. Mode of operation System status TO FEED: DISPENSED: GROSS: STOP Scales 560kg 733kg 3440kg 12.5V Target weight to feed Dispensed amount Amount in machine Connectivity status Battery voltage System battery indicator Features: The top line shows the weight to feed out before a beeper sounds. The second line shows the weight dispensed since GO was pressed. The third line shows the tare or gross weight in the machine. The bottom line of the screen shows the mode of operation (Scales), the battery voltage (highest voltage available to the unit. When disconnected from the tractor, this will be the internal battery voltage), and connectivity status. Operating Notes: The operator can adjust the weight to be dispensed by adjusting the TO FEED figure. This is done by pressing UP or DOWN on the keypad when the TO FEED figure is underlined. Use the RIGHT or LEFT button to move the underline cursor. The operator can select between gross and tare weight to be displayed by pressing TARE/GROSS on the keypad. The operator can zero only the dispensed weight by pressing GO on the keypad. To allow the dispensed weight to accumulate and the target feed weight to work, the operator must press GO before commencing feeding. The operator can zero the gross weight and dispensed weight by pressing ZERO on the keypad. Screen Warnings: None

11 11 Installation Section Remote display #TCS-V2DISP Component Layout 12 24VDC Supply (Tractor battery) Brown - Positive Blue - Negative Cab switch Install loom #TCS-LOOM1 (with box) Install loom #TCS-LOOM1V2 (no box) 5A Fuse Cable from battery to switch (5m) Remote display cable #TCS CABLE Cable from switch to tractor plug (2m) #LIGHTLED-RH #LIGHTLED-LH Tail lights Wheel sensor (5m) #TCS-OEM-PROX Power module Weight module #TCS-V2PB #TCS-V2WGTMOD Load cells (4 or 6) #ES-WLY00003P Battery cable (0.55m) #TCS-V2CABBAT Data cable (1m) #TCS-V2CABWGT 5A Fuse Battery #TCS-BATTERY2 Controller #TCS-V2CONTR Controller power cable (1m) #TCS-V2CABCON 7 core cable (5.5m) with plug #TCS-LOOM2 Valve cable #TCS-V2CABVAL 7 pin plug #PLUG7PINM Valve assembly #HYSUPERVC-DPBM

12 12 Remote Display Mounting & Power Supply The Remote Display is designed to be mounted in the tractor cab and be easily accessible to the driver. It contains a radio frequency (RF) communication device to control the Forage Wagon Controller (Controller). It will require shielding from the weather elements of sun and rain etc. The Remote Display requires volts DC to operate. It will typically only draw 0.2A. The power supply must originate from the tractor battery as part of the installation loom (supplied with the machine). Forage Wagon Controller & Power Supply The Forage Wagon Controller is powered from the tractor while operating. When disconnected from the tractor, it draws power from its own sealed lead acid battery. No installation wiring is required on the Forage Wagon. The tractor requires an installation loom (supplied) which provides a switched and fused positive and negative supply from the tractor battery to the rear 7-pin socket. The tractor battery is the best power supply point as it provides the most stable and quiet power source. Do not use any other power source. Wagon plug: Tractor Plug RF positive supply (BLACK) wire to be in pin 2 RF positive supply from wiring loom (BROWN) RF negative supply from wiring loom (BLUE) RF negative supply (BLUE) wire to be combined with (WHITE) wire into pin 3 There are three CPC connectors on the Controller module. If a connector is not used, place the terminal cap over it. Terminal cap

13 13 Mounting the Modules Modules should be mounted as illustrated. Power wires should be kept separate where possible from the load cell cables. Only 2 screws are required at opposite corners of each module. Keep all cables clear of moving parts. Control Module Control Module mounting bracket Battery Power Module Battery base plate Run power cables this side Run load cell cables this side Weight Module

14 14 Setting the RFID Number The RFID Number setup screen is used to assign a wireless address to the Controller. This feature is available to prevent interference between two systems when they are operated in close proximity to each other. To access the Remote Display RFID screen, re-power the display and press and hold the MODE button until a setup screen appears. RFID Number 1.00 The operator can press the UP button or the DOWN button to adjust this value. Press GO to enter then STOP to escape. Re-power the Remote Display to access the new channel. Controller Settings After removing the Controller cover, a DIP switch with 8 white switches is visible. DIP switches The D.I.P. (dual inline plastic) switches which are labelled 1 to 8 are used to select the RF channel ID. The switch is considered to be on when switched to the right hand side. The channel ID of the Controller MUST match the software setting of the Remote Display. If the channel ID is changed in either the Remote Display or Controller then you must re-power both devices for the new setting to take effect. To re-power the Controller, unplug the POWER cable for 5 seconds. The DIP switch settings are shown in the following table. Switch On 0 None RFID #

15 15 Fitting the Power Module Circuit Board The power board will need to be fitted if load cells are fitted. It is fitted into the power module. Open the Power Module lid. Remove the wire joining block. Fit the circuit board with the supplied screws. Attach the wires as noted on the board. Remove white wire from Power Module to control module cable and install Red, Green and Blue wires into Power Module circuit Board. Fitting the Wheel Sensor The wheel (proximity) sensor has to be adjusted halfway between the range of being always on and always off. This is approximately 5mm between the end of the sensor and the wheel plate. Take care when running the cable that there is enough slack to allow the axle to fully oscillate. Approx. 5mm

16 16 Fitting the Load Cells Fit the studs to the load cell first before fitting the load cells to the machine using the bolts provided. Lower the top half of the wagon onto the studs. Tighten the top nut then back off ½ turn. Route the wiring through the pipe/brackets provided through to the junction box taking care to keep the wiring tidy and away from moving objects. Concave washer Convex washer Load cell Stud and nut Recommended Load Cell Bolt Torque Settings M ft/lbs or 380Nm M ft/lbs or 660Nm Note: If installing PT brand load cells, there will be two extra blue and brown wires. Connect the Sense +ve (brown) together with Excitation +ve (red) and Sense ve (blue) together with Excitation ve (black). Weight Module Connection When fitting load cells or a wheel sensor, see below for fitting information about connecting wires into the weight module. Insert screw driver for top layer here Top layer Insert screw driver for bottom layer here Bottom layer

17 17 Setting System Parameters Parameters are required to be set for the machine to function correctly. Entering Configuration Screens To enter set-up, press TARE/GROSS and ZERO together for 4 seconds or until the set-up screen appears. Press UP or DOWN to adjust the parameter. Press MODE to move to the next configuration screen. It will save what is displayed on the screen. Press STOP to exit the configuration screens. Scale Damping Value The Scale Damping Value parameter is a weighting value over which the weight is averaged. A higher value will display a smoother weight display but won t react to weight changes as quickly. value. Press MODE to continue. Load Cell Type The Load Cell Type parameter specifies the maximum load for each individual load cell used on the wagon. value. Press MODE to continue. Number of Load Cells The Number of Load Cells parameter specifies the total amount of load cells fitted to the machine. Enter 0 if no load cells are fitted. value. Press MODE to continue. Load Cell Sensitivity The Load Cell Sens. parameter specifies sensitivity of the load cells used on the wagon. The setting is in mv per Volt. This means mv output per Volt of excitation. This is a characteristic of the load cells used. value. Press MODE to continue. Scale Damping Value Load Cell Type kg Number of Load Cells Load Cell Sens. 2.00mV/V 0-10

18 18 Scale Hysteresis The Scale Hysteresis parameter specifies how much a weight reading needs to change before the reading on the screen will change. value. Press MODE to continue. Scale Increments The Scale Increments parameter specifies minimum scale increment displayed on the screen. value. Press MODE to continue. Scale Hysteresis 10.00kg Scale Increments 10.00kg Maximum Valve Pressure The Max Valve PSI parameter sets the elevator load sensing pressure. Reduce this value if the elevator Max Valve PSI stalls too often. Ideally this should be set approximately PSI below tractor relief psi pressure. value. Press MODE to continue. Wheel Sensor Fitted The Wheel Sensor Fitted parameter indicates if the wheel sensor is fitted or not and displays appropriate modes to suit. value. Press MODE to continue. Wheel Diameter The Wheel Diameter parameter is used to calibrate the wheel size on the machine. value. Note: For accuracy, measure from the ground to the centre of the hub (and double) when the machine is half loaded. This will compensate for tyre pressure. Press MODE to continue. Number of Wheel Holes The Number of Wheel Holes parameter is used to calibrate the distance measurement for the number of holes on the encoder disk used by the speed sensor. value. Press MODE to continue. Wheel Sensor Fitted YES 0-1 Wheel Diameter mm No. of Wheel Holes

19 19 Low Battery Level The "Low Batt Level" parameter defines the minimum battery voltage level at which the screen will switch from displaying voltage to displaying LOBAT. This function can be cancelled by setting the voltage to 0.00V. value. Press MODE to continue. Solenoid Valve Fitted The Valve Fitted parameter indicates if the solenoid valve is fitted or not and displays appropriate modes to suit. value. Press MODE to continue. Minimum Valve Setting The "Min Valve Setting" parameter defines the minimum valve opening percentage when in Distance and Speed mode, while running. When stopped, the valve will go to 0. value. Press MODE to continue. Valve Ramp Up Time The Valve Ramp Up Time parameter changes the valve ramp up time. value. Press MODE to continue. Valve Ramp Down Time The Valve Ramp Down Time parameter changes the valve ramp down time. value. Press MODE to continue. Valve Start-up for Distance Setting The Valve Startup Dist. parameter is the initial valve setting to use when the machine is started in Distance mode. value. Press MODE to continue. Low Batt Level 11.50V 0-30 Valve Fitted YES 0-1 Min Valve Setting Valve Ramp Up Time 0.00sec 0-10 Valve Ramp Up Time 0.00sec 0-10 Valve Startup Dist % 0-100

20 20 Minimum Speed while in Speed Mode The "Speed Mode Min Speed" parameter is only used for Speed mode. It defines the minimum speed the machine must be moving before the machine begins to operate. This function is adjustable between 0 and 5 km/h, with increments of 0.1km/h. value. Press MODE to continue. Speed Mode Min Speed 1.00km/h 0-5 Maximum Speed while in Speed Mode The "Speed Mode Max Speed" parameter is only used while in Speed mode. It defines the theoretical Speed Mode Max maximum speed the machine will reach at which point the machine will be operating at maximum feed rate. Speed The lower this is set, the more aggressive the machine 10.00km/h will operate. This function is adjustable between 1 and km/h with increments of 1km/h. Any speed over this parameter will cause the machine to run at the percentage setting on the display. value. Press MODE to continue. Speed Mode Start-up Time The "Speed Mode Strt. Time" parameter is only used while in Speed mode. It defines the length of time the Speed Mode Strt. machine must be moving above the minimum speed before it begins its usual function. This function is Time adjustable between 1 and 20 seconds with increments 1.00sec of 1 second value. Press MODE to continue. Distance before Finish The "Dist. Before Finish" parameter is only used while in Distance mode. It defines the length before the end of the run at which the valve controller will return to Dist. Before Finish zero hence stopping the floor operation and clearing 1.00m 0-10 the machine. When set on zero, the machine will continue functioning until the distance reads zero. This function is adjustable between 0 and 10 metres with increments of 0.5 m. value. Press MODE to continue. Shut Down Timer The shut down timer controls the time that the Controller will stay powered up while running on battery power. value. Press MODE to continue. Shut Down Timer 20.00min 1-60

21 21 Checking Setup Parameters A Function screen is available to check current settings. To enter, press and hold the left arrow for three or more seconds. The top line shows the requested valve position. The second line shows the present gross load weight. The third line shows the current machine ground speed. The bottom line of the screen shows the current mode of operation (Std), the Controller software revision and connectivity status. The Function mode screen is shown below: Current operating mode VALVE: GROSS: SPEED: MODE:Std 38% 2850kg 5.65km/h Rev 3.5 Requested valve position Gross weight Ground speed Controller software revision By pressing the UP or DOWN buttons, you can scroll and view parameters. They cannot be changed here. Press GO or STOP to exit and return to the operating screen.

22 22 Factory Parameter Settings Software Revision: Remote Display 3.4, Controller 3.8 To enter set-up, press TARE/GROSS and ZERO together for 4 seconds or until the setup screen appears. Press MODE until the correct parameter is displayed. Press UP or DOWN to adjust the parameter. Press STOP to exit the configuration screens. Remove power from the Controller to update changes. Parameter Scale Damping Value Load Cell Type Number Of Load Cells Load Cell Sens. Scale Hysteresis Scale Increments Wheel Sensor Fitted Wheel Diameter No. of Wheel Holes Low Batt Level Valve Fitted Max Valve PSI Min Valve Setting Valve Ramp Up Time Valve Ramp Down Time Valve Startup Dist. Speed Mode Min Speed Speed Mode Max Speed Speed Mode Strt Time Dist. Before Finish Shut Down Timer Value kg mv/v (PT) or 2.20mV/V (Kelba) 2.00mV/V kg (PT) kg Yes mm or 23 (check) V Yes psi % 0.00 sec 0.00 sec % 1.00 km/h km/h 1.00 sec 1.00 m min Note: These are factory default settings. Some machines will require different settings.

23 23 Final Check Check that the Controller is working correctly: Plug in the 7-pin plug into the tractor and turn on the power switch. This applies power to the Controller. The POWER LED on the Controller should be illuminated. Unplug the 7-pin tractor plug. A battery power symbol ( ) will show on the screen which indicates the system is running on battery power and the wagon is not plugged into the tractor. After disconnecting the 7 pin plug and waiting 20 minutes (depending on parameter setting), the Controller should power down. If tractor power is reapplied, the Controller will restart. Note: To force power off and preserve battery power, press and hold the OFF button on the Controller when tractor power is disconnected. Check that the Power module is working correctly: When the wagon is plugged in the tractor, voltage should be higher than when unplugged. Plugged in should read approx V. Unplugged should read approx V. Check that there is RF communication: There should be an antenna symbol ( ) displayed in the bottom right hand side of the screen. Check that the valve (if fitted) is working correctly: Change the mode to Std, increase the FEED RATE to 100% and press GO. The Controller LED will be illuminated when the valve reaches 100% setting and the valve solenoid will make a light buzzing noise. The wagon floor chain should start and stop when GO or STOP is pressed. System hydraulic pressure can sometimes cause the floor to not quite stop. In this case, increase tractor revs and recheck. Check that the load scales (if fitted) are weighing correctly: This can be done by applying a known load to the floor after zeroing. The Weight module LED labelled Weight should be illuminated whenever the system is running. If the weight display is unstable when stationary, charging the battery will help. The voltage will be displayed on the lower line of the screen. When the system is running on battery power, a ( ) symbol will display alongside the voltage reading. Check that the wheel sensor (if fitted) is working correctly: Jack up the wheel with the wheel sensor fitted and check that the sensor light blinks for each hole while the wheel rotates. The green LED labelled PROX in the weight module should also blink at the same time as the sensor light. In distance mode, dial up a distance of say 20 metres on the Remote Display and press GO. Rotate the wheel 2-3 revolutions (forward or reverse) and check that the distance is decreasing. All complete: Ship with battery connected (it will power down to preserve power).

24 24 Technical Section Power and Charging The wagon must be connected to the tractor for the floor control solenoid (if fitted) to function and to charge the system battery. When load cells are fitted, the forage wagon also includes a battery. This is charged automatically from the tractor power. The tractor does not need to be running (but can be) for this to happen but the wagon does need to be plugged in and power turned on. If the battery is flat, this will usually take 7-8 hours depending on the age, state, and cycling pattern the battery has experienced. The Controller will continue to measure and report weight for approx 20 minutes after the tractor has been disconnected. This enables the operator to load the wagon using the tractor and still read the wagon weight. It then turns itself off if not plugged into the tractor within this time. If the controller begins to lose communication or the weight reading becomes unstable with the forage wagon when unplugged, it may be because the battery is weak or flat. The battery voltage indicator should show this. Battery voltage (12V 7Ahr SLA) State of charge % % % % % % % % % % % Avoid discharging the battery below the 40% level whenever possible.

25 25 System Display LEDs There are LEDs located on the Controller panel and inside the Weight module to indicate operational status. Controller Module Power LED The Power LED will be illuminated if: 1. Tractor power is connected or 2. The battery is connected and the Controller is still running. RF LED The RF LED will flash when the Controller receives an RF message. Pressing a button on the Remote Display instigates RF messages to the Controller. Note: The antenna symbol ( ) on the Remote Display indicates that it is receiving RF messages. Weight LED The Weight LED will be illuminated when a message is received from the Weight module. Valve LED The Valve LED will be illuminated when: 1. Required valve percentage is greater than 5% and 2. Actual valve percentage is within 2% of required valve percentage and 3. Controller is receiving current feedback from valve. Weight Module Prox LED The Prox LED will be illuminated when the wheel sensor senses ferrous metal. Comms LED The Comms LED will be illuminated when receiving data from the Controller. Weight LED The Weight LED will be illuminated when the load cells are connected correctly and the weight is within a valid range (100kg load per cell or greater) I.e. off for a short circuit or an open circuit, on otherwise. Power LED The Power LED will be illuminated if 12V power is supplied.

26 26 System Safety Fuses The entire control system is protected by three separate fuses located in various positions. 1. Installation loom fuse This is located on the positive (+) wire at the power source end of the installation loom. This protects the entire system from short circuits. The fuse used is a 5A (yellow) automotive blade type (see below). 2. Battery cable fuse This is located on the positive (+) wire of the battery connection cable. This protects the charge system against reverse polarity from incorrect battery connection. The fuse used is a 5A (yellow) automotive blade type (see above). 3. Power charge circuit board fuse This is located on the power charge circuit board to protect the system from short circuits particularly if fuse #1 has been replaced with a heavier rating or similar. The fuse used is an M205 8A. Radio Frequency Device The Remote Display communicates with the wagon by a wireless link and must be within range of the forage wagon for the system to operate correctly. If the Remote Display is not able to communicate with the Controller, the antenna symbol ( ) will disappear or not show. Common reasons are: Local interference from a strong radio frequency source such as cell phone, power pylons or R.T. site. Distance between the Remote Display and Controller is too great. (Moving back within range will allow the system to begin operating again.) No power to the Controller (not plugged into tractor power or if fitted with a battery has auto-powered off). Physical medium in the signal path from the Remote Display to the forage wagon (e.g. metal farm shed). Remote Display and Controller operating on different RF channels. Interference being caused by an adjacent farm using similar machinery. RF channel should be changed to prevent further interference.

27 27 Wiring Schematic

28 28 Wiring Schematic V2

29 29 Cable Descriptions TCS-LOOM2 Tractor Cable 7 pin plug to power module board Pin # Wire Colour Description 1 Yellow Left flasher 2 Black RF (+) supply 3 White and Blue Earth and RF(-) 4 Green Right flasher 5 Empty Red Stop light 7 Brown Tail light 7-Pin plug (viewed from rear of plug) TCS-V2LOOM1 Tractor Installation Loom Wire Description Wire Colour Connects to: Positive Brown Tractor battery & 7-pin plug (pin 2) Negative Blue Tractor battery & 7-pin plug (pin 3) Positive White Remote display plug Negative Blue Remote display plug 7-Pin socket (viewed from rear of plug) TCS-V2CABBAT Battery Cable Battery to power module board Wire Description Wire Colour Positive Brown Negative Blue TCS-V2CABCON Power Cable (Red sheath) Controller plug to power module Pin # Wire Colour Description 1 Red V+ out Tractor 3 Blue V+ out Battery 4 Green 0V out

30 30 TCS-V2CABVAL Controller Plug Pin # 1 4 TCS-V2CABWGT Pin # Valve Cable Controller plug to valve plug Wire Colour Valve Plug Pin # Brown 1 Blue 2 Weight Cable (White sheath) Controller plug to weight module Wire Colour Description Red V in White D+ Blue DGreen 0V Controller end plug 1 4 Valve end plug Remote Display Screen Contrast The contrast of the remote display screen can be altered by following the instructions below. 1. Remove the back cover plate. 2. Locate blue adjuster pot on the top circuit board. 3. Adjust yellow screw in centre of pot (clockwise for lighter text). Caution: Adjuster is very sensitive. Note: Opening the back cover voids the factory warranty. Check with the dealer first if unsure. Software Revisions Hardware Date Rev Comments Controller module First release of Generation II Adjusted weight field for one more digit. Adjusted scales mode so that mode button does not reset TO FEED Weight. Display module First release of Generation II Weight module First release of Generation II

31 31 Fault Diagnosis Problem Issue Solution Check fuse in Power module Controller won t turn on when wagon is plugged into tractor Power not getting to Controller Check fuse in wiring loom Check wiring from tractor Controller won t turn on when the GO button (on Controller) is pressed. Battery is disconnected or flat Reconnect or recharge battery Battery fuse blown Replace fuse Plug wagon into tractor to recharge battery Connect battery Battery flat or not holding charge Controller won t stay turned on when unplugged Battery not connected Battery fuse blown Controller not operating No communication indicator ( ) showing on Remote Display Signal interference from another machine Distance too great between Controller and Remote Display Signal blocked by large object Controller and Remote Display are operating on different channels Floor won t move forward when in Standard or Weight mode. Floor not moving forward when in Distance or Speed mode Scales won t read at all or display reads 0kg Move closer together Move away from object Change both units to the same channel and re-power Loose or faulty load cell wiring Load cell cables getting interference from power cables Power not getting to Controller System not started Press GO on keypad Feed rate too low Damaged valve cable or faulty solenoid coil Power not getting to Controller Increase feed rate System not started Press GO on keypad Faulty proximity sensor or wiring Replace sensor/check wiring Unscrew override knob (anticlockwise) Screw out override knob or replace valve cartridge if faulty Press STOP on keypad Override knob is screwed in Floor won t stop coming forward Change RF channel Check wiring from tractor and fuse in power module Check load cell wiring Separate load cell and power cables Check plugs and wiring Low battery voltage Scale reading fluctuates Replace fuse Check wiring from tractor and fuse in power module Faulty override cartridge System still running Loose, faulty or incorrect load cell wiring Weight module not connected Check cable and/or coil Check plugs and wiring Check load cell wiring Check connection

32 32 Troubleshooting Chart