AgXcel GX5 Install Guide for Integration into Trimble. where precision meets the soil... PO Box 1611 Kearney, NE

Transcription

1 where precision meets the soil... AgXcel GX5 Install Guide for Integration into Trimble PO Box 1611 Kearney, NE where precision meets the soil...

2 AgXcel Integration into the Trimble System AgXcel Precision Fertilizer Application Systems (FAS) are designed to integrate into various OEM controllers. This installation guide will assist in the controller configuration settings for the in-cab monitor. The integration process begins with the users purchase and installation of the corresponding OEM's Liquid Rate Control Module, The picture below displays the Trimble Rate Controller with the AgXcel integration harnesses. Each Trimble Rate Controller can control one product. Therefore, if you were applying two liquid fertilizers on you planter, you will need three rate controllers, one for seed and two for liquid fertilizer. The harness coming out of the Trimble rate controller is a 37 pin amp connector that will be connected to the AgXcel 30 pin amp connector extending from the AgXcel GX system. Trimble Rate and Section Control Module 30 Pin AgXcel connector harness part number Pin Connector Connects to Trimble Harness back to in cab display This harness connect to the AgXcel harness PWM 16 pin round connector for pump control and the AgXcel harness section or section harness 2 Pin Power Connector (P5) This connects to the AgXcel harness for power 2 AgX Integrate Into Trimble 03/26/12 December 24, :39 AM Version 1.01

3 Trimble Rate and Section Control Module 18 Pin Connector A B C D E F G H I J K 30 Pin Connector 30 Pin Connector 18 Pin Connector Connects to Trimble Harness back to in cab display 30 Pin Connector This harness connects to the AgXcel integration harness P/N Common Troubleshooting Guidelines: PWM Signal to Pump: Pins E1 to E2 should have 0-12 volts to turn pump on. Use manual mode to increase signal. Should get up to 12 volts after holding increase button. Flow meter Tap Test: Pins C2 and C3 are Flow Ground and Signal. If no flow is registering on the display, you can tap between these two pins with a short wire. This produces a pulse. The display should indicate a flow when this is done rapidly. 3 AgX Integrate Into Trimble 03/26/12 December 24, :39 AM Version 1.01

4 Trimble Field-IQ Setup The Trimble Field-IQ is a very flexible control platform with many capabilities. This section will show you the detailed steps to setup your Trimble Field-IQ to control your AgX Fertilizer System. Home Screen Navigation Buttons Home Setup - Diagnostics Run Screen Note: If you are using Firmware 8.5 you must use the following steps. 1. Start from scratch! Delete equipment and start fresh in Field-IQ. 2. Perform an Auto Tune and set Max Flow to Set the PWM Drive to close System Information From the home screen, you can select 3 tabs; Support, System Information or Camera. The System Information tab is shown above. This will show what Trimble components are properly connected to your display. If your fertilizer system quits functioning, first check that the Control Module is still recognized on the display. If not, inspect the Trimble wiring harness connections or consult your Trimble dealer. CFX-750 and FM750 Users Information in this manual is applicable to the 750 except for screen shots shown in the Setup & Operation. The calibration and setup values in this section DO apply to the 750. However, the 750 has a completely different screen layout and menu structure that is not shown in this manual. Use your Trimble manual to navigate, then enter the appro-priate numbers from the Ag X manual. 4

5 Configuration - Setup & Calibrate In the Setup & Calibrate menus you will set the Trimble Field-IQ to work properly with the AgX Fertilizer System. Carefully follow these steps to first make the proper settings. Then, run the tests shown to verify your fertilizer system is ready to go to the field. 1. From the home screen choose Setup & Diagnostics. 2. The Configuration screen below will appear. Choose Field- IQ. The Setup & Calibrate buttons will be locked, shown by a padlock next to them. 3. Push Setup, then enter After entering the code, the locks will disappear. Push Setup to proceed to the next steps. 5

6 Setup - Material 1. Press Add to setup the material being used. If you already have a material setup, then select it and press Edit 1. Under the Material Tab, Choose material type Liquid 2. Give the material a name that makes sense. 3. Press the Setup button to take you to the rate setup. 6

7 Setup - Material (continued) & Layout Rate setup is where you will set the Field-IQ default application rates. 1. Set Rate 1 & Rate 2 to two application rates you will use (in GPA). 2. Typically, rate increment is 1.0 GPA (the amount rate changes using + or - buttons on Field-IQ) 3. Leave Manual Rate Increment at 100%. 4. Leave Minimum Rate at 0 gal/a. 5. Set Maximum Rate high enough so that it does not limit you. 1. If adding press next to get to the layout tab, or if in edit mode, just press the Layout tab. 2. Then press the Bin/Tank Setup button. 7

8 Setup - Layout (continued) Tank Setup allows you to enter your tank size then the Field IQ system will calculate the volume left in your tank and warn you at a certain level. These settings do not impact the AgX Fertilizer System performance in any way. Set status to ON if you would like to use this feature. 8

9 Setup - Section Control Press the Setup button next to Section Control Module Location to take you to the Section Control Module Setup. 1. Set the Number of Modules in your system. 2. Select the Serial Number for each Module. 3. Set the number of sections for your fertilizer system. Press Section Widths button. 9

10 Setup - Section Control (continued) 1. Set the width of your sections. Press the Setup button next to Section Control to take you to the Section Control Setup. 10

11 Setup - Section Control (continued) 1. Set Section Control Type to Boom Valve 2. Set Off When Stopped to Yes. 3. Press Latency button to setup latency. 1. Set On Latency to 0.50 s, set Off Latency to 0. Adjust these as necessary in field 11

12 Setup - Rate Control 1. Set Rate Control to On 2. Set Off When Stopped to Yes. 3. Set Total Nozzles to the number of rows or delivery points on your implement. 4. Press Setup button next to Rate Control Module Location. 1. Module serial number should be the same as in the Section Control Module setup. The width should reflect the values you entered in the Section Control Module setup. 12

13 Setup - Rate Control (continued) 1. Press the Setup button next to Drive Setup. 1. Use the settings in the picture for valve control setup. 13

14 Setup - Rate Control(continued) See Chart 1. Flow Meter Type Other 2. Flowmeter Calibration: ION Flowmeter: see chart Micro-Trak Turbine Flowmeter: # on tag 2 3. Minimum Flow: Typically leave at 0.0 GPM. Can be set to the minimum specification for the flowmeter. 14

15 Setup - Operation F 1. Jump Start Speed is the speed the fertilizer system will ramp up to when the operator pushes the Jump Start button mph is recommended, if you want to use this optional feature. 2. Leave Minimum Override Speed at 0.0, so Jump Start will work at any speed or sitting still. 3. AgX recommends Rate Snapping On. With this off, the application rate shown on the Trimble Field IQ will fluctuate constantly due to very small, but continuous, changes in ground speed and fertilizer flow. 15

16 Implement Setup Implement Setup is where you set the information for the implement you are using. Mainly these settings affect the guidance control. However if using auto section shutoff, these settings will determine when each section valve shuts off. Measure your implement carefully and consult your Trimble dealer for additional assistance with the Implement Setup section. 16

17 Calibrate To enter the calibration menus, return to Configuration, then push Calibrate. In calibration, you must go to Drive Calibration & Flow Calibration. The Pressure Calibration is only necessary if you are using an optional pressure sensor to display fertilizer system pressure on the display. Implement Lift switch will show up if it is enabled in the Setup menu. Implement Lift Switch Calibration If the optional Implement Lift Switch is Enabled in the Setup menus, it will show up in the calibration list above. The lift switch MUST be calibrated before it will function. It can be calibrated in either polarity (Implement up = switch open OR Implement up = switch closed) Pressure Calibration The optional pressure sensor must be calibrated with a manual pressure gauge. You will enter the gauge pressure with system off (may not be quite zero due to check valve pressure). Then turn the system on (Master on, Manual Mode, Increase switch to get a higher pressure) and enter the higher gauge pressure. 17

18 Drive Calibration These screens setup the operational parameters of the PWM signal. On the Drive Limits screen set the Maximum flow to match your flow meter. Then press the next key to take you to the Auto-Tuning tab. At this point, press the next button to go to the Drive Settings tab. We skipped the Auto-Tune and are going to setup the Drive Calibration manually. The settings on the Drive Settings screen are all duplicated on the Advanced Parameters screen. Press the Advanced Parameters button to go to the next screen. 18

19 Drive Calibration (continued) % 1.0% 28 Hz These settings adjust the limits of PWM signal going to the electric pump. These settings are recommended for the AgXcel GX5 System. Use this setting to smooth the Flow Rate. Raising this value will cause the flow rate to change more slowly. Lowering it will cause the flow rate to change more rapidly. 10% is recommended. 19

20 Flow Calibration In Flow Calibration you will enter the flow meter information. Then run the calibration where you will perform a catch test to verify proper operation. We already entered these settings in the Drive Setup but you can update or verify the settings here. See Chart 1. Flow Meter Type Other 2. Flowmeter Calibration: ION Flowmeter: see chart Micro-Trak Turbine Flowmeter: # on tag 2 3. Minimum Flow: Typically leave at 0.0 GPM. Can be set to the minimum specification for the flowmeter. 20

21 Flow Calibration - Catch Test RETURN TO THIS SECTION & RUN THE CATCH TEST AFTER THE SYSTEM IS PRIMED AND TESTED. This procedure will automatically recalculate the Flow Calibriation (pulses / gallon) based on the amount you catch and enter in the display. With an ion flowmeter, the final flow calibration should be very close to the standard number. You need to conduct a very accurate catch test to improve the flow calibration value. AgXcel recommends running the procedure to make sure all information is entered correctly, then likely changing the flow calibration back to the standard value. After pushing Run Calibration the screen below will appear. Enter your typical application rate and field speed. During calibration, the system will run at the correct flow for this rate and speed. 21

22 Flow Calibration - Catch Test (cont.) Now you need to measure the amount of liquid caught. The number you enter must be in gallons per minute per row. 1. Find total amount caught in ounces. 2. Divide total ounces by number of rows caught. 3. Divide ounces / row by 128 to convert to gallons / row. 4. If test was 1 minute long, enter number from step 3. If test was more than 1 minute divide #3 answer by number of minutes to get gallons / minute / row. Example: 100 ounces 4 rows caught = 25 ounces / row 25 ounces / row 128 ounces / gallon = gallons / row gallons / row 2 minutes = gallons / minute / row Enter in Measured Flow/Nozzle field The Trimble Field IQ will round the number you enter to two decimal places. This may be significant if you are applying lower rates of fertilizer. We recommend running this proce dure to verify all set up is completed correctly. We recommend changing the flow calibration back to the standard ion flow meter calibration shown on the flow calibration page previously. After entering the amount caught, the Flow Calibration number will automatically change. If it has changed more than 5%, review your catch test and repeat. AgX recommends re-entering the number below for best accuracy. The calculator button will bring up an on screen calculator so you can do the math outlined above. 22

23 A Initial Operation Instructions A gx highly recommends you perform these exact steps with water to verify system is correctly installed and ready for field use. From the Configuration Screen, select Field-IQ, then Diagnostics. Turn on the AgXcel GX5 Hydraulic Valve 1. Press the + next to speed to simulate a speed signal. 2. Turn the Field-IQ master switch (#5) on. 3. Push each section valve button and verify each valve is working. 4. Turn Switch #2 to Manual and open the section valves. Use switch #1 to increase flow. Does Current Flow display a flow rate? Is it stable after the system is primed. Do increase & decrease buttons increase & decrease flow? 5. Move switch #2 to Rate 1 and set speed to your typical field speed. 6. The system should begin to pump liquid now in automatic control mode. Is the flow in GPM stable? Is it applying at the correct rate? (applied rate = target rate?) 7. Change rate using screen buttons or switch #1 to increase/decrease rate or switch #2 to go to Rate 2. Does applied rate change to equal target? 8. Close 1 section valve, does flow decrease? Does applied rate still equal target rate? 9. Change speed and target rate to minimum and maximum values. Does system perform at these values? Does the system pressure seem reasonable (remember fertilizer will increase pressure over water)? 23

24 Fertilizer System Flow Charts Use the correct implement width chart to find the required pump flow (in gallons per minute) based on travel speed and application rate 24

25 Fertilizer System Flow Charts Use the correct implement width chart to find the required pump flow (in gallons per minute) based on travel speed and application rate 25

26 Troubleshooting Pump Will Not Turn Turn hydraulics off, go to the AgXcel PWM valve and use the manual override on top of the electric coil to manually open the valve (Manual Override UP = valve fully open). Turn hydraulics on at a low flow only as the valve is 100% open. Try hydraulic lever in opposite direction. Does the pump turn? If it turns, your problem is electric / electronic. If the pump still does not turn, you have a hydraulic problem. Electric / Electronic Problem 1. Close manual override (lock down) 2. Go to Diagnostics, Section Test to investigate this issue. 3. Verify hydraulics are on. 4. In Section Test, hold down + button for a few seconds. A single tap of this button produces a very small change in signal to the valve, so you must hold it. 5. Take a metal object and hold it next to the coil. If the coil is working, you will feel the magnetic pull. 6. If no magnetic force is felt, disconnect the PWM valve connector and check voltage. You will need 6-12 volts to get hydraulic valve to open. 7. If 6-12 volts is not present, check harnesses and review control valve type setup. 8. Go back to the 30 pin connector at thetrimble Rate Controller. Check voltage between pins E1 & E2, should be between 6-12 volts while in section test after holding + button. 9. If you cannot get voltage at pins 15 & 16, contact your Trimble dealer for further assistance. Hydraulics Problem 1. Leave the manual override open on the AgXcel valve. 2. Check the hose routings. The P port on the AgXcel valve should hook to pressure. The T port is the return that should flow back to the tractor. 3. Try hoses in a different hydraulic remote. Inspect hydraulic connectors for damage or restrictions. Hydraulic Manual Override Down - Normal Operation Up - Override, valve 100% open PO Box 1611 Kearney, NE

27 Troubleshooting Section Valve(s) will not move 1. Go to Diagnostics, Section Test to investigate this issue. 2. In Section Test, check and uncheck the boxes. With the box checked the valve should turn on. The valve should be off with the box not checked. 3. Do you have a problem with 1 valve or all valves. 4. If working with the 7-12 section harness, identify if section 1-6 or section 7-12 One Valve doesn t work 1. Check the harness connection to that valve. It is a 3 Pin Weather Pack connector. See Section D for wiring diagrams Pin Function A + 12 V Constant B GND C + 12 V Signal 2.. Check voltage pin A to Pin B. Must be 12 volts, if not, go back to 16 pin & 37 pin connector and check voltage. 3. If no voltage on 30 pin connector from Trimble Rate Controller, contact your local dealer for assistance. 4. If voltage is present on pins A&B of 3 pin connection to valve, then check pin C to Pin B. This should be 12 volts when the valve is com-manded on or open, this should be zero volts when valve is off or closed. 5. If signal voltage is not present to open valve, use diagrams to check at the 16 pin, then the 30 pin for volt-age. 6. If constant voltage (Pins A&B) and switched voltage (Pins C&B) are present, inspect, repair or replace the valve. All or multiple valves don t work 1. Generally, follow the same steps as for a single valve. However, concentrate on checking for constant voltage on Pins A & B, then follow that back to the 16 pin and 30 pin connectors. 2. This problem could also be related to display configuration. Review Implement Setup to make sure sections are correct in controller. PO Box 1611 Kearney, NE

28 Troubleshooting Application Rate Fluctuates First, you need to determine if the fluctuation is caused by the controller sending fluctuating signals to the valve. 1. Go to Diagnostics screen. 2. Turn the system on watch the flow in GPM. 3. Is the flow steady within a very small range. For example a fluctuation from 12.3 to 12.6 GPM would be considered normal. A fluctuation from GPM is a problem. If only a small normal fluctuation is seen in section test, skip steps 4-8 and proceed to Application Rate Fluctuates in Field.. below. 4. If there is a large fluctuation, observe the system flow. Is the discharge a steady stream; are the flow indicator balls floating steady. 5. If visually the flow is steady, but the display reports a fluctuation in GPM, inspect the flowmeter. 6. If visually the flow is unsteady, the flowmeter is working correctly reporting a flow problem. Is the pump turning steady or surging? 7. If the pump is turning steady, the hydraulic circuit is functioning correctly. Look for any type of obstruction in the pump inlet. Clean the strainer. If continually plugging the strainer investigate fertilizer quality and necessary strainer size. 8. If the pump speed is surging, there is a hydraulic problem. Application Rate fluctuates in field, but flow in Section Test mode is stable. This problem indicates the valve calibration needs changed. The system is surging because the Rate Controller is moving the hydraulic valve too much. 1. Go to Field IQ - Calibration - Drive Calibration. 2. Change the settings by reducing the Integral Gain. Application Rate is slow to get to the Target Rate 1. You may need to increase the valve calibration. Go to Field IQ - Calibration - Drive Calibration. 2. Change the settings by increasing the Integral Gain. 3. At Field IQ, Diagnostics make sure the Aggressiveness is at 100% to 150%. 4. If the system is slow getting to Target Rate on start up after performing the above steps, set the Minimum Response to a higher number. OR 1. You may need to increase the PWM Low Limit. When the rate has to increase from zero flow, the valve will begin at a higher point. The initial recommended setting is 60. If you increase this value too much the pump will not be able to reach the minimum flow necessary with only 1 section open or a slow field speed. 28 PO Box 1611 Kearney, NE

29 Diaphragm Pump Valves & Diaphragms All GX5 models use the same diaphragm and valve parts. Diaphragm Pump Service Kit 1 Kit contains 1 diaphragm and 2 valves to service a single pumping diaphragm. Order multiple kits to service all the diaphragms in your pump per chart at right. Diaphragm & Valve Service Steps: 1. Drain oil from pump. Rotate pump shaft to remove all oil. 2. Remove pump manifold(s) using a 17mm or 13 mm wrench. 3. Remove and replace complete valve assembly. 4. Remove the pump head. 5. Remove the diaphragm bolt, support washer and diaphragm. Turn the pump shaft to up stroke to replace diaphragm. 6. Install new diaphragm, then replace washer and bolt. 7. Turn pump to downstroke to seat new diaphragm into the sleeve groove. 8. Replace pump head and manifold(s). 9. Refill crankcase with SAE30 non detergent oil (Hypro Oil or hydraulic jack oil). Number of Diaphragms D70 2 D115 3 D160 4 D250 6 Valves are on same side of head. Valves should pop out with slight screwdriver pressure. Valves (not shown) are arranged on opposite sides of head. 29 PO Box 1611 Kearney, NE

30 D70 Diaphragm Pump Part Number Description Inlet HB Elbow, 1 1/ Inlet Ring Nut Inlet O-Ring Inlet Threaded Adapter Outlet HB Elbow, Outlet Ring Nut Outlet O-Ring Outlet Threaded Adapter HYD2495 Motor Flange & Coupler Kit Sight Glass Sight Glass Bottom O-Ring Sight Glass Cap Sight Glass Cap O-Ring D115 Diaphragm Pump Part Number Description Inlet HB Elbow, 1 1/ Inlet Ring Nut Inlet O-Ring Inlet Threaded Adapter Outlet HB Elbow, Outlet Ring Nut Outlet O-Ring Outlet Threaded Adapter HYD2495 Motor Flange & Coupler Kit Sight Glass Sight Glass Bottom O-Ring Sight Glass Cap Sight Glass Cap O-Ring 30 PO Box 1611 Kearney, NE

31 D160 Diaphragm Pump Part Number Description Inlet HB Elbow, Inlet Ring Nut Inlet O-Ring Inlet Threaded Adapter Outlet HB Elbow, Outlet Ring Nut Outlet O-Ring Outlet Threaded Adapter HYD1570 Motor Flange & Coupler Kit Sight Glass Sight Glass Bottom Gasket Sight Glass Cap Sight Glass Cap O-Ring D250 Diaphragm Pump Part Number Description Inlet HB Elbow, Inlet Ring Nut Inlet O-Ring None Inlet Threaded Adapter Outlet HB Elbow, 1 1/ Outlet Ring Nut Outlet O-Ring Outlet Threaded Adapter HYD1570 Motor Flange & Coupler Kit Sight Glass Sight Glass Bottom Gasket Sight Glass Cap Sight Glass Cap O-Ring 31 PO Box 1611 Kearney, NE

32 Recommended Care and Maintenance Winterization AgXcel recommends flushing your fertilizer pump and complete system with adequate amounts of water first. Next, use RV antifreeze to winterize your system by pumping an adequate amount through all components. At the beginning of the next season, begin with water to verify the system is in working order Change Pump Oil Annually GX5 pumps use an internal oil lubricated crankshaft and connecting rod design. The oil is held in an external reservoir with level indicators. Hypro oil is recommended for the pump. This is a non-detergent SAE30 weight oil. If not available, hydraulic jack oils are a similar non-detergent formulation. Annual oil changes are recommended. To fill or drain the pump completely, the pump shaft must be turned slowly by hand. The hydraulic motor will have to be removed to do this. On some pump models, the pump will have to be removed from the mounting bracket and lifted slightly to allow access to the oil plug. When refilling the pump with oil, the shaft will again have to be rotated to fill the pump to its required oil volume. Diaphragm & Valve Replacement GX5 pumps are designed to allow very simple replacement of the two main pumping components; the diaphragms and the inlet & outlet valves. It is a good practice to replace these annually. It is a small job that helps ensure reliable operation during the busy season. copyright AgXcel LLC 32 PO Box 1611 Kearney, NE