technical manual supplement - giltrapag.co.nz · generation i rf control system – operating,...

RF Control System RF Control System

Technical Manual Supplement Technical Manual Supplement

OPINT software revision 2.16 – RIO software revision 3.7 OPINT software revision 2.16 – RIO software revision 3.7

GETTING STARTED..................................................................................................................................................... 2

GENERAL SETUP INSTRUCTIONS ................................................................................................................................ 2

INSTALLATION ........................................................................................................................................................... 3 Forage Wagon Operator Interface Mounting & Power Supply............................................................................ 3 Forage Wagon Electronics ................................................................................................................................... 3 Wiring Schematic .................................................................................................................................................. 4 Forage Wagon Power and Charging .................................................................................................................... 5 Aerial Position ...................................................................................................................................................... 5 Cable Descriptions................................................................................................................................................ 6 Trailer Plug Wiring Connection ........................................................................................................................... 7 Tractor Plug Wiring Connection........................................................................................................................... 7 Amplifier Set-Up Procedure.................................................................................................................................. 8 Amplifier Plug Wiring........................................................................................................................................... 8 Remote IO Box Dip Switch Settings ...................................................................................................................... 9

USER OPERATING INSTRUCTIONS ............................................................................................................................ 10

Manual Valve Over-ride Function ...................................................................................................................... 10 Radio Frequency Device ..................................................................................................................................... 10 RIO Box Start/Reset Button................................................................................................................................. 10 Start-up Screen.................................................................................................................................................... 11 Standard Screen .................................................................................................................................................. 11 Additional Features............................................................................................................................................. 11 Weight Screen ..................................................................................................................................................... 12 Distance Screen................................................................................................................................................... 13 Speed Screen ....................................................................................................................................................... 14 Scales Screen....................................................................................................................................................... 15

INSTALLER CONFIGURATION INSTRUCTIONS ........................................................................................................... 16 CONTROL MODE OPTIONS ....................................................................................................................................... 21 UPGRADE KIT (WEIGHT & DISTANCE MODES)......................................................................................................... 23 UPGRADE INSTALL PROCEDURE .............................................................................................................................. 24 FITTING THE LOAD CELLS........................................................................................................................................ 26 FITTING THE JUNCTION BOX .................................................................................................................................... 27 FITTING THE SPEED SENSOR .................................................................................................................................... 27 QUICK CHECK SETTINGS ......................................................................................................................................... 28 FINAL CHECK........................................................................................................................................................... 31 RADIO FREQUENCY SYSTEM FAULT DIAGNOSIS...................................................................................................... 32

Generation I RF Control System – Operating, Installation & Technical Manual

RF System Technical Manual Rev2_16.doc

2

Getting Started A controller, mounted on the tractor uses wireless technology to relay data from the wagon to display the feed rate, load weights or feed-out amounts (depending on options purchased), allowing the operator to control discharge rates using different modes. The operator can also use the time saving controller functions – for example; entering ‘distance’ and ‘quantity required’, the controller automatically adjusts feed-out rates for accurate unloading. 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 discharge rate when needed, all while on the move.

General Setup Instructions There are five options available: • Scales (Scales mode – no rate control) • Scales (Weight mode – includes rate control) • Rate Control (Standard mode) • Ground Speed Compensation (Speed mode – no scales) • Full Automatic Control (Distance mode) Forage Wagon OPINT: Connect the OPINT as on Page 3. Standard Forage Wagon Electronics: Mount the RIO box on the forage wagon. Connect the Power/Amplifier cables power lead (2.5m) to the tractor plug on the wagon. Connect the Power/Amplifier cable (0.4m) connector to the amplifier. Plug the Power/Amplifier cable into the RIO box. Weight Upgrade: Connect the Load Cell/Speed Sensor cable to the RIO box. Connect each of the seven cores to separate terminals in the junction box. Connect the load cells to the corresponding terminals in the junction box. See page 27 for details. Distance Upgrade: Connect the Speed Sensor to the corresponding terminals in the junction box. See page 27 for details. Final Check: See page 31 for details.



3

Installation Forage Wagon Operator Interface Mounting & Power Supply The Forage Wagon Operator Interface (OPINT) 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 Remote Input Output (RIO) Box. It will require shielding from the weather elements of sun and rain etc. The OPINT is powered by the tractors 12 volt power supply. It will typically only draw 0.2A. The supply should be switched and fused i.e. taken from the fuse box on the tractor. The monitor cable is supplied for this purpose. Table 1

OPINT Cable WHITE Tractor Positive (12-24VDC) BLUE Tractor Negative / Earth

Forage Wagon Electronics There are two connectors on the Forage Wagon Electronics (RIO Box). A standard system is provided with the Power/Amplifier cable (9 pin plug) providing connections to the tractor power and to the amplifier. A fully featured (weight or distance) system also requires the Load Cell/Speed Sensor cable (7 pin plug) providing connections for the load cells and the speed sensor. Note: If the 7-way connector is not used place the sealing cap over the unused connector.

Amplifier RIO Box Start/Restart Button Aerial



4

Wiring Schematic Trailer lights

White – Positive Blue - Negative Wheel sensor

RIO box

Amplifier / Coil / Valve Assembly

Load cells (4 or 6)

Power/Amplifier cable

Scale/Wheel sensor cable

Aerial

Cab mountedmonitor

Junction box

5A Fuse

12 – 24VDC SupplyBrown (Positive) Blue (Negative) Cab

switch

Brown – Positive Blue - Negative



5

Forage Wagon Power and Charging • With a standard system, the RIO box must be connected for the forage wagon electronics

to function. • With a fully featured system, the forage wagon electronics also include an internal battery.

This is charged automatically from the tractor power which must measure at least 13.0VDC at the plug.

• The RIO box will continue to measure and report weight for 30 minutes after the wagon

power has been disconnected. It then turns itself off. This will enable the operator to load the wagon using the tractor and still read the wagon weight.

• If the controller begins to lose communication with the forage wagon when unplugged, it

may be because this internal battery is weak or flat. • To charge the battery run the system with the tractor power connected until the battery is

sufficiently charged. This usually takes 3-4 hours depending on the age, state, and cycling pattern the battery has experienced.

• If unable to sustain reasonable charge in the battery, an optional external charger may be

required. Contact your dealer for this. Table 2

Internal Battery Voltage (12V 2.3Ahr SLA)

State of charge

12.6+ 100% 12.5 90%

12.42 80% 12.32 70% 12.20 60% 12.06 50% 11.9 40%

11.75 30% 11.58 20% 11.31 10% 10.5 0%

Avoid discharging the battery below the 40% level whenever possible.

Aerial Position When initially fitting the RIO box to the machine, care must be taken to route the aerial away from the box yet still retain a clear area around the end 75mm. Failure to do so will cause the system to have a short transmission range and may give erratic readings. See the photo on page 3 for further layout details.



6

Cable Descriptions Table 3

Power/Amplifier Cable

Wire Description Cable Colour Connects to Pin #

Power GND Blue Tractor GND 1

Power 12V Brown Tractor Switched 12V 2

Amplifier GND Blue Amplifier Connector 4

Amplifier 12V Brown Amplifier Connector 5

Amplifier Signal Green/Yellow Amplifier Connector 6 Table 4

Load Cell/Speed Sensor Cable

Junction Box Connections Load Cells/Speed Sensor Cable

Item Description Colour Junction Colour Pin #

Ground (0V) Blue White/Green 3

12V (V+) Brown Green 4 Speed Sensor

Signal (PX) Black Orange 5

Signal – White White/Orange 6

Signal + Green Blue 7

Excite + Red White/Blue 2 Load Cells

(4 or 6)

Excite - Black & Shield Black (Shield) 1

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).

1

2

6

5

4

7 4 6

Power/Amplifier Cable Load Cell/Speed Sensor Cable

1

5

2

3



7

Trailer Plug Wiring Connection

Indicator Green or Blue

Indicator White

Auxiliary (RF Positive) Red or Brown

Earth (RF Negative)

Spare

Tail/Park Light Yellow

Brake Light Red

Black & Yellow or Blue

Tractor Plug Wiring Connection

Positive (key activated

Earth

Note: While this wiring configuration may not be suited to all tractors, it is important that the wiring is checked during installation to ensure that the RIO box has power. The positive terminal must measure between 13 - 14.5 VDC (tractor engine running) and be able to supply at least 5A when the key is activated.



8

Amplifier Set-Up Procedure

When powered up, the display shows the input or output signal, as pre-selected. To enter set-up mode rotate SELECT. The decimal points will start to flash and the display will show the ssequentially: HI, LO, UP, dn, Cd, dF, di and SA.

ettings

When you reach the setting that you want to modify, rotate ADJUST up or down to the desired value. To modify another setting, rotate SELECT again and repeat. The driver is fully functional during the set-up procedure with any adjustments effective immediately. In order to write the new settings in the memory and return to normal mode of operation, rotate SELECT until the display shows SA, and then rotate ADJUST or wait for 100 seconds. Note: If you do not want to keep the new settings, you must disconnect the driver from the power supply before the end of 100 seconds in order to restore the old settings. Table 5

Display Description Range Setting HI High 25-98 45 LO Low 02-HI 00 UP Ramp up 00-99 00 dn Ramp down 00-99 00 Cd Command deadband 00-05 00 dF Dither frequency 08-30 16 di Signal displayed 00 or 01 00

Amplifier Plug Wiring E Blank Not used

1 Brown Positive 2 Blue Ground 3 Green/Yellow Command Signal

E

1 2

3

Table 6



9

Remote IO Box Dip Switch Settings With the cover

removed from the RIO Box, a DIP switch with 8 white switches is visible at the top left of motherboard.

• The D.I.P. (dual inline plastic) switches which are labelled 1 to 8 are used to select the RF Channel ID.

• The channel ID of the RIO box MUST match the software setting of the OPINT.

• If the channel ID is changed in either the OPINT or RIO Box then you must re-power both devices for the new setting to take effect. This is because at power up the RF module requests which channel to communicate on.

• To re-power the RIO box, unplug both the tractor plug and the internal battery plug before plugging in again or wait 30 minutes for the box to automatically switch off.

• The weighting if the DIP switches is binary (1,2,4,8,16,32,64,128), and can be shown by example in Table 7.

Table 7

RFID # 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 1 3 1 2 1 4 1 1 1 3 1 2 2 3 3 2 4 2 2 4 3 3 Switch On

Non

e

3 4 4 4



10

User Operating Instructions

Manual Valve Over-ride Function When RF control is fitted to the machine, there is also a manual over-ride function. For normal operation, the screw adjuster must be unscrewed all the way out and the locking ring tightened. This function over-rides all RF control. Use 1/8 turn adjustments per time. Don’t over-adjust.

Label on cover IMPORTANT

Manual over-ride located beneath this cover

To operate in case of electronic malfunction, undo locking ring

and screw in adjuster.

Use 1/8 turn adjustments.Over-ride adjuster

Radio Frequency Device The OPINT 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 OPINT is not able to communicate with the wagon, the in-range 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 OPINT and forage wagon is too great. (Moving back within range

will allow the system to operate again.) • No power to the RIO box (not plugged into tractor power or if fitted with a battery has auto-

powered off after 30 minutes.) • Physical medium in the signal path from the OPINT to the forage wagon (e.g. metal farm

shed). • Different RF channel between the display and the wagon electronics. The number on the

screen indicates what RF channel the system is using. This is factory set. If interference is being caused by an adjacent farm using similar machinery, then the RF channel should be changed to prevent further interference.

RIO Box Start/Reset Button There is a green illuminated button located on the side of the RIO box. This indicates when there is power at the RIO box. When used with a fully featured system, this button is used to activate the RIO box without the need to plug the tractor in. It will also reactivate the system when it has auto-powered off after 30 minutes.

Start/Reset Button



11

Start-up Screen When the OPINT 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 ENGINEERING LTD RF FORAGE WAGON

Rev 2.16

OPINT software revision

Standard Screen In standard mode, the feed-out is a set rate shown by the rate percentage. This rate is shown on the top line of the screen. The standard operating screen is shown below.

Feed Rate System status Mode of operation RF channel

RATE: 50% STOP Std 1

Connectivity status

• The operator can adjust the rate percentage figure. This is done by pressing or

on the keypad.

• The operator can start and stop the feed-out by pressing or on the keypad.

Additional Features If the system is a weight or distance model then the Standard screen will display additional information.

• The second line will show the weight dispensed since the wagon was loaded. • 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), the RF channel and connectivity status.

STOP

START

Dispensed amount

Amount in machine

Battery voltage

Feed Rate RATE: 50% DISP: 1050kg GROSS: 2950kg STOP Std 12.5V 1

• The operator can switch to the Weight, Distance, Speed or Scales operating screens

(if enabled) by pressing on the keypad.

MODE

• The operator can zero the gross and dispensed weight by pressing on the keypad.

ZERO

• The operator can zero only the dispensed weight by pressing on the keypad.

START

• The operator can select between gross and tare weight to be displayed by pressing

or on the keypad.

TARE

GROSS



12

Weight Screen In Weight mode, the feed-out is a kilogram per minute rate.

• The top line shows the feed-out rate. • The second line shows the weight fed out since the wagon was loaded. • 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), the RF channel and connectivity status.

The Weight mode screen is shown below. Feed Rate

Dispensed amount

Amount in machine

RATE: 1000kg/min DISP: 560kg GROSS: 3440kg STOP Weight 12.5V 1

Mode of operation

System status Battery voltage

• The operator can select the feed-out rate by adjusting the rate kg/min figure. This is

done by pressing or on the keypad.

• The operator can start and stop the feed-out by pressing or on the keypad.

START

STOP

• The operator can switch to the Standard, Distance, Speed or Scales operating

screens by pressing on the keypad.

MODE


ZERO


START


or on the keypad.

TARE

GROSS



13

Distance Screen In Distance mode, the feed rate is automatically set by dispensing weight over a set distance.

• The top line shows the weight to dispense.

• The centre of the second line shows the distance travelled since was pressed. The right side of the screen shows the distance over which to feed out 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), the RF channel and connectivity status.

The Distance mode screen is shown below. The operator can adjust the weight to be dispensed by adjusting the DISP (dispense) figure.

This is done by pressing or on the keypad when the DISP figure is selected. The DISP figure is selected when the last digit in the weight is underlined.

• The operator can adjust the distance to dispense the weight over by adjusting the

OVER figure. This is done by pressing or on the keypad when the OVER figure is selected. The OVER figure is selected when the last digit in the distance is underlined.

• The operator can select the DISP or OVER figures by pressing on the keypad.

Overall distance

Amount in machine

Distance travelled

Amount to dispense DISP: 1800kg OVER: 52m 100m GROSS: 3540kg STOP Dist 12.5V 1

START

• The operator can start or stop the feed-out by pressing or on the keypad.

START

STOP

• The operator can switch to the Standard, Weight or Speed operating screens by

pressing on the keypad.

MODE


ZERO


START


or on the keypad.

TARE

GROSS



14

Speed Screen In Speed mode the feed-out is set to a particular rate at a reference speed. The unit continuously monitors the ground speed and maintains a consistent feed-out rate relative to the ground speed.

• The top line shows the discharge rate. • 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), the RF channel and connectivity status.

Note: If only a proximity sensor is fitted but no scales, no battery is required; so set the minimum battery voltage to 0.00V (see page 87). The Speed mode screen is shown below.

• The operator can select the feed-out rate by adjusting the rate percentage figure.

This is done by pressing or on the keypad.

RATE: 12% DISP: 940kg GROSS: 3540kg STOP Speed 12.5V 1

Dispense rate Dispensed weight Weight in machine

• The operator can start or stop the feed-out by pressing or on the keypad.

START

STOP

• The operator can switch between Standard, Weight and Distance operating screens

by pressing on the keypad.

MODE


ZERO


START


or on the keypad.

TARE

GROSS

Note: There is a small time delay of around 3 seconds before the feed-out rate of the product will change to adjust to the new tractor speed. Depending on the setup of the controller, the maximum speed for uniform feed-out rate is between 1 and 20km/h. Over 20km/h, the system will not be able to maintain a uniform feed-out rate due to dynamic constraints.



15

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 or the display is fitted to the loading tractor.

• The top line shows the weight fed out since the wagon was loaded. • The second line shows the weight of the current load. This may be gross or tare. • 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), the RF channel and connectivity status.

The Scales mode screen is shown below.

DISP: 560kg GROSS: 3440kg Scales 12.5V 1

Dispensed amount Amount in machine Mode of operation

• The operator can zero the gross weight and dispensed weight by pressing on the keypad.

ZERO


START


or on the keypad.

TARE

GROSS

• To allow the dispensed weight to accumulate, the operator must press before commencing feeding.

START

• The operator can switch between Standard, Distance and Speed operating screens

(if enabled) by pressing on the keypad.

MODE



16

Installer Configuration Instructions Entering Configuration Screens

• To enter set-up, press and together for 3 seconds or until the set-up screen appears.

• Press the or to change the configuration parameter.

• Press to accept the parameter change.

• Press to move to the next configuration screen.

• Press to exit the configuration screens.

*** SETUP *** Forage Wagon Model Distance

*** SETUP *** Scale Damping Value 1.00sec

*** SETUP *** Load Cell Type 5000.00kg

*** SETUP *** Number of Load Cells 4.00

Forage Wagon Model The “Forage Wagon Model” parameter is used to enable the different screens depending on the options available.

The operator can press or to select between Standard, Weight, Distance and Scales modes.

ZERO

TARE

ENTER

MODE

ESCAPE

Press to accept.

ENTER

Scale Damping Value The “Scale Damping Value” parameter is a time period over which the weight is averaged. This is to average out weight measurement variance due to wagon movement.

The operator can press or to adjust this value.

Press to accept.

ENTER

Load Cell Type The “Load Cell Type” parameter specifies the maximum load for each individual load cell used on the wagon.

The operator can press or to adjust this value to

either 5000 or 10000. Press to accept.

Number of Load Cells The “Number of Load Cells” parameter specifies the total amount of load cells fitted to the machine.


Press to accept.

ENTER

ENTER

Load Cell Sensitivity



17

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.

*** SETUP *** Load Cell Sens. 2.00mV/V


Press to accept.

*** SETUP *** Scale Hysteresis 10.00kg

*** SETUP *** Scale Increments 10.00kg

*** SETUP *** Valve Min. cal. 4017.00cn

*** SETUP *** Weight H/W Rev V4-41-B

Weight Board Hardware Revision The “Weight H/W Rev” parameter specifies the weight board revision fitted. This is usually specified on the board itself.

The operator can press or to adjust this value. Press ENT to accept.

Scale Hysteresis The “Scale Hysteresis” parameter specifies how much a weight reading needs to change before the reading on the screen will change.


Press to accept.

Scale Increments The “Scale Increments” parameter specifies minimum scale increment displayed on the screen.


Press to accept.

Valve Minimum Calibration The “Valve Min. cal” parameter is used to calibrate the RIO box output for full scale on the valve controller. When calibrating the amplifier output, adjust this value until the amplifier display reads as close as possible to 00%. This number is displayed on the amplifier itself – see page 76.

The operator can press or to adjust this value

while watching the amplifier display screen. Press to accept.

ENTER

ENTER

ENTER

ENTER



18

Valve Maximum Calibration The “Valve Max. cal.” parameter is used to calibrate the RIO box output for minimum scale on the valve controller. When calibrating the amplifier output, adjust this value until the amplifier display reads as close as possible to 99%. This number is displayed on the amplifier itself – see page 76.

*** SETUP *** Valve Max. cal. 3667.00cn

The operator can press or to adjust this value while watching the amplifier display

screen. Press to accept.

ENTER

Wheel Diameter The “Wheel Diameter” setup screen is used to calibrate the distance measurement for the size if the wheel on the forage wagon.

*** SETUP *** Wheel Diameter 760.00mm The operator can press or to adjust this value.

Press to accept.

*** SETUP *** No. of Wheel Holes 15.00

*** SETUP *** RFID Number 1.00

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.

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.

The operator can or to adjust this value.

Press to accept.

RFID Channel Number The “RFID Number” parameter is used to assign a wireless address to the Controller. This feature is available if two systems are operated in close proximity. In the case of interference between two systems, set one system to a different RF channel number. Note: If this number is changed in the Forage Wagon Controller the same number must be set on the RIO box DIP switch. All units will be factory delivered with an RF ID number of 1. There are 256 channels available.

The operator can press or to adjust this value. Press to accept.

ENTER

ENTER

ENTER

See page 77 to change RIO box RF channel number.



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.

*** SETUP *** Low Batt Level 11.00V


Press to accept.

*** SETUP *** Startup V. Set. Dis 85.00%

*** SETUP *** Minimum V. Setting 50.00

*** SETUP *** Min. F.R. kg/min 400.00kg

Startup Valve Setting Distance The “Startup V. Set. Dis” parameter is the initial valve setting to use when the machine is started in Distance mode.

The operator can press or to adjust this value. This should be set to 50% for feed pad situations.

Press to accept.

Startup Valve Setting Weight The “Startup V. Set. kg/m” parameter is the initial valve setting to use when the machine is started in Weight mode.

The operator can press or to adjust this value. This should be set to 50% for feed pad situations.

Press to accept.

Minimum Valve Setting The "Min. V. Setting" parameter defines the minimum valve setting when in Weight and Distance modes, while running. When stopped, the valve will go to 0.


Press to accept.

Minimum Feed Rate Setting The “Min. F.R. kg/min" parameter defines the minimum feed rate in kg/min that the system is capable of controlling while in the Weight mode.


Press to accept.

ENTER

ENTER

ENTER

ENTER

ENTER

*** SETUP *** Startup V. Set. Kg/m 85.00%



20

Minimum Speed while in Speed Mode The "Speed Mode Min Speed" parameter is only used while in 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.

*** SETUP *** Speed Mode Min Speed 1.00km/h


*** SETUP *** Speed Mode Strt Time 1.00sec

*** SETUP *** Dist. Before Finish 1.00m

*** SETUP *** Speed Mode Max Speed 6.00km/h

Maximum Speed while in Speed Mode The "Speed Mode Max Speed" parameter is only used while in Speed mode. It defines the theoretical maximum speed the machine will reach at which point the machine will be operating at maximum speed. The lower this is set, the more aggressive the machine will operate. This function is adjustable between 1 and 20 km/h with increments of 1km/h. Any speed over this parameter will cause the machine to run at 100% (full speed).


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 machine must be moving above the minimum speed before it begins its usual function. This function is adjustable between 1 and 20 seconds with increments of 1 second.


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 zero hence stopping the floor operation and clearing 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.


ENTER

ENTER

ENTER

ENTER



21

Control Mode Options Control Option 1 – Standard Mode Standard Mode – The operator controls the feed out rate through a percentage range from 0 to 100%. Only standard board fitted.

No extra boards fitted.

Control Option 2 – Weight Mode Weight Mode must the have the weight and input/out boards fitted to the RIO box and load scales fitted to the machine. The operator determines the feed out rate in kg/minute.

Load cells fitted Weight board fitted Input/output board fitted



22

Control Option 3 – Distance Mode Distance Mode must have the weight board, input/output board, wheel sensor and load scales fitted. The wagon will unload the required amount over the required distance, and will compensate for changes in ground speed.

Control Option 4 – Speed Mode Speed Mode must have the input/output board and wheel sensor fitted. 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.

Input/output board fitted

Wheel sensor fitted

Wheel sensor fitted

Load cells fitted

Weight board fitted Input/output board fitted



23

Upgrade Kit (Weight & Distance modes) The upgrade kit allows a standard; minimally configured forage wagon system to be upgraded to a full-specification all options enabled system. These instructions assume the OPINT and the RIO box are already fitted and operational on the forage wagon. The extra features depending on upgrade options are:

• Option 1 – Rate control only (Standard mode)

• Option 2 – Weighing of wagon payload (Scales mode)

• Option 1 + 2 – Weighing of payload and dispensing kg per metre (Weight mode)

• Option 3 – Feed pad rate control (Distance mode plus also has Speed mode)

• Option 4 – Dispensing feed per metre (Speed mode)

The procedure to upgrade the standard forage wagon is as follows:

• Enable extra features in the keypad. See page 84 for full details.

• Upgrade the hardware in the RIO box. (Plug in circuit boards, install load cells and speed sensor to wagon, install junction box and fit appropriate wiring to new sensors.)

Parts List The upgrade kit consists of the following items: 1x Junction box for load cell wiring 1x Strip terminal connector (to join wires if junction box is blank) 1x Load cell/speed sensor cable (7 core) to junction box 1x SLA (sealed lead acid) 12V, 2.3Ah battery 1x Circuit board, part description v4-35A (input/output circuit board) 1x Circuit board, part description v4-41B (weigh circuit board) Available separately: 1x Speed sensor with cable



24

Upgrade Install Procedure OPINT upgrade:


• A screen similar to the one below should be displayed:

• If the above screen is not displayed, continue pressing until it shows.

• Press until Weight, Distance (if speed sensor is fitted) or Scales is displayed.

• Press to accept.

ENTER

MODE

*** SETUP *** Forage Wagon Model Standard

ZERO TARE

• Press to exit the configuration screens.

ESCAPE

• Remove power from controller. RIO box upgrade:

1. Disconnect the tractor power (9-pin plug) from the side of the RIO box.

2. Remove the cover from the RIO box after removing any built up dirt from around the lid and check that there are no lights on the circuit board.

3. Either remove the RIO box from the forage wagon (preferable) or perform the upgrade while the RIO box is fitted (more difficult but possible).

4. Remove the screws holding down the base plate in the RIO box and fit the 12V battery underneath the base plate. The base plate holds the battery in place.

5. Make sure the positive terminal of the battery is on the right hand side of the box when viewing and then refit the screws to hold down the base plate and battery.

6. Fit the red and black flying leads to the battery using long nose pliers. The green plug can be connected to the main circuit board after the circuit boards have been fitted.

7. On an antistatic workbench, and using an antistatic wrist strap, remove the 2 circuit boards from the antistatic bags and place them on top of the antistatic bags ready to install.

8. Fit the circuit boards. The boards may need trimming to fit along side each other. Sandpaper can be used to carefully reduce the width of the board. Fit the weight board (labelled v4-41B) to the 2nd slot (2nd from left hand side). Fit the Input/Output board (labelled v4-35A with 4 green rectangular LEDS mounted vertically and at the bottom of the circuit board) in the 3rd slot from the left hand side of the motherboard. Make sure the screws are used to hold down the circuit boards in place (small Philips screwdriver).

CAUTION!! THE PINS ON THE BOTTOM OF THE CIRCUIT BOARDS ARE VERY EASY TO BEND. IF BENT, YOU WILL MOST LIKELY NEED A NEW CIRCUIT BOARD.



25

9. Fit the RIO box back onto the wagon.

10. Connect the new 7-way connector to the RIO Box.

11. Fit the junction box to a suitable position on the wagon. See page 95 for details.

12. Connect the Load Cell/Speed Sensor Cable to the RIO box.

13. Connect each of the seven cores to separate terminals in the junction box.

14. Connect the load cells to the corresponding terminals in the junction box. See page 74 for cable termination.

Remote IO Box Layout Standard RIO Box

RF Channel Switch Amplifier Controller Board (36C) Software version Fuse

Motherboard (34B) Daughterboard (47B)

RIO Box with Weight & Distance upgrade

Weight Board (41B) Input/output Board (35A) LEDS Battery Plug

Speed sensor Tractor power Power on Not used



26

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. • Connect wires as per Table 8 or see Page 74, Table 4.

Concave washer Convex washer Load cell Stud and nut

Recommended Load Cell Torque Settings M20 - 280 ft/lbs or 380Nm

M24 - 490 ft/lbs or 660Nm

Important Note: If a strip connector was used as a junction, wrap insulation tape around the entire connector to prevent earth shorts.

Table 8

Load Cells Load Cells/Speed Sensor Cable

Description Colour Junction Colour Pin #

Signal – White White/Orange 6 Signal + Green Blue 7 Excite + Red White/Blue 2 Excite - Black & Shield Black (Shield) 1



27

Fitting the Junction Box Mount the junction box on the main cross member at the rear of the drawbar on the left hand side. Drill and fix the box to the chassis using self-tapping screws.

Load Cells Junction Box

Fitting the Speed Sensor

• The speed (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.

• Connect wires as per Table 9 or see Page 74, Table 4. Approx. 5mm

Table 9

Speed Sensor Load Cells/Speed Sensor Cable Description Colour Junction Colour Pin #

Ground (0V) Blue White/Green 3

12V (V+) Brown Green 4

Signal (PX) Black Orange 5



28

Fitting the In-line Battery Charging Circuit Board Parts Supplied • Circuit board • Ribbon cable set Fitting Instructions 1. Remove the lid from the white RIO box. 2. Remove the ribbon cable and centre screw from the metal base plate. Remove screw 3. Wipe the base plate clean with a dry cloth then remove the backing tape from the

adhesive feet on the circuit board and stick onto the metal base plate so the remaining screws can still be accessed.

Adhesive feet (x3) 4. Install the new ribbon cable. It is multi-directional but be sure that the small plugs are

fitted to the closest large plug. It is possible to fit connectors in the incorrect place and although this would not cause damage, it would result in the system malfunction.

The battery can now be charged by leaving the ignition key on. The charge circuit will do the rest.



29

Setting up a 240V 3-pin Charger System Parts Supplied • 13.8VDC @ 0.8A 3-pin Charger

• 7-pin Female Tractor Plug

Trailer Plug Wiring Connection (viewed from front, looking at pins)

Auxiliary Indicator (RF Positive) Green or Blue

Important Note: While this wiring configuration may not be suited to all tractors, it is important that the wiring is checked during installation to ensure that the RIO box has power and is able to draw 5A constantly when the ignition key is turned on. 240V Auxiliary Charging When fitting a plug to a charging adapter, check the voltage of each pin to determine the correct wiring layout. The plug attached to the charger MUST be wired the same as the tractor.

Do not use this charger in conjunction with the inline charging circuit (pictured on the previous page).

Indicator White

Red or Brown

Brake Light Earth Red (RF Negative) Black & Yellow or Blue

Tail/Park Light Yellow

Spare



30

Quick Check Settings Software Revision: OPINT 2.16, RIO Box 2.7 Note: These are factory default settings. Some machines will require different settings.

Monitor Set-up Procedure


• Press until Weight, Distance (if speed sensor is fitted) or Scales is displayed.

• Press to accept.

• Press to exit the configuration screens. • Remove power from controller.

Table 10 Forage Wagon Model Standard, Weight, Distance or Scales Scale Damping Value 1.00 sec Load Cell Type 5000.00 kg Number Of Load Cells 4.00 Load Cell Sens. 2.20mV/V (Kelba) or 2.00mV/V (PT) Weight H/W Rev V4-41-B Scale Hysteresis 10.00 kg Scale Increments 10.00 kg Valve Min. Cal. 4017.00 cn. Valve Max. Cal. 3667.00 cn. Wheel Diameter 760.00 mm No. of Wheel Holes 15.00 RFID Number 1.00 (must match RIO Box settings) Low Batt Level 11.00V Startup V. Set. Dis. 85.00% Startup V. Set. Kg/m 85.00% Min. V. Setting 30.00 Min. F. R. Kg/Min 400.00kg Speed Mode Min Speed 1.00 km/h Speed Mode Max Speed 6.00 km/h Speed Mode Strt Time 1.00 sec Dist. Before Finish 1.00 m If any values were changed, press ENTER before continuing to the next setting. Press ESCAPE to exit. Note: Not all settings are used in STANDARD mode but should be set for future use.

ESCAPE

ENTER

ZERO TARE



31

Final Check Check that the power circuit board is working correctly: Connect the internal battery leads to the battery (red is positive, black is negative) and connect the battery lead plug to the green socket at the bottom left corner of the circuit board. The RIO box will NOT turn on yet – this is normal. Plug in the 7 pin light/power plug to the tractor and turn on the ignition. This applies power to the RIO box. With the RIO box cover still removed, check that the 2 green LED’s (the two centre LED’s of the four) on the input/output board are glowing. Turn the tractor ignition off and check the green LED’s. The third from left (power on) should be glowing while the second from left (tractor power) should be off. After a time delay of 30 minutes, the RIO box should power down. If tractor power is reapplied, this countdown timer is reset. Note: To force power off, disconnect the internal battery and the tractor plug. Check that there is RF communication: There should be a ( ) symbol displayed in the bottom right hand side of the screen. Check that the amplifier (if fitted) is working correctly: Select Standard mode.

Press on the OPINT and adjust the feed rate to 100%. The amplifier display should read between 97-99%. Check again by changing the feed rate to 50% and 0%. The display should show an appropriate number.

START

Check that the load scales (if fitted) are weighing correctly: This can be done by applying a load to the load cells after zeroing the scales. If the weight display is changing significantly, altering the mounting location of the RF aerial will help. Charging the internal battery will help if the weight is unstable when unplugged from the tractor. The source voltage will be displayed on the lower line of the screen. Check that the speed sensor (if fitted) is working correctly: Jack up the wheel with the speed sensor fitted and check that the sensor light blinks while the wheel rotates. The green LED (first on left of the 4 square shaped LED’s) on the input/output board should also blink at the same time as the speed sensor light.

In distance mode, dial up a distance of say 20 metres on the OPINT and press . Rotate the wheel 2-3 revolutions (forward or reverse) and check that the distance is decreasing.

START

All complete – ship with battery connected (it will power down to preserve power).



32

Radio Frequency System Fault Diagnosis

Problem Issue Solution

Check fuse in RIO box Green light on RIO box won’t illuminate when wagon is plugged into tractor

Power not getting to RIO box Check wiring from tractor

Green light won’t stay illuminated when unplugged

Internal battery flat or not holding charge

Plug wagon into tractor to recharge battery

RIO box not active Check fuse in RIO box. Check wiring from tractor. Press green button on RIO box if fitted

Signal interference from another machine Change RF channel

Distance to great between RIO and OPINT Move closer together

Signal blocked by large object. Move away from object

No communication indicator ( )showing on OPINT

Aerial not working correctly Check aerial for damage or incorrect position

Low internal battery voltage Check fuse in RIO box. Check wiring from tractor Scale reading fluctuates

Loose or faulty load cell wiring Check load cell wiring

System not started Press on keypad Feed rate too low Increase feed rate Faulty solenoid coil Replace coil No power to unit on wagon Check plugs and wiring Signal not getting to amplifier Replace 36C circuit board

Floor won’t move forward while in Standard mode.

No power to unit on wagon Check plugs and wiring Floor not moving forward in Distance or Speed mode Faulty proximity sensor or wiring Replace sensor/check wiring

Floor won’t stop coming forward Faulty override cartridge Replace valve cartridge (with hydraulic type)

Circuitry not holding power Replace input/output board Fully configured RIO box won’t hold power when tractor source removed Battery not fully charged Recharge battery

Faulty weight board Replace weight board Scales won’t read at all or display reads 0 Loose, faulty or incorrect load cell

wiring Check load cell wiring

Keypad unable to enter setup Faulty keypad Return for repair OPINT will not store settings correctly

Memory not operating correctly. Possible faulty memory chip. Return for repair

Incorrect weight board version in V2.16 software Change OPINT parameter Voltage reading displays differently

than when voltage is tested Incorrect board positions Check if boards have been incorrectly placed

No communication signal Check power is getting to IO box on machine

OPINT not started Press on keypad OPINT set on zero Increase feed rate

Amplifier displays 00 and won’t change

Incorrect parameters Check parameters

No power coming from tractor Check power is getting to IO box on machine Amplifier is blank

Faulty amplifier Replace amplifier

START

START

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