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Giltrap 595-0036, Instructions, Operating, Installation

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GILTRAP GENERATION II 

RF CONTROL SYSTEM 

 

Operating, Installation & Technical Manual 

Part Number: 595-0036 

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

 

R

EMOTE 

D

ISPLAY 

S

CREENS

 ................................................................................................................................. 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................................................................................................................................................. 10

 

Installation Section ...................................................................................................... 11

 

Component Layout ........................................................................................................................................ 11

 

Remote Display Mounting & Power Supply .................................................................................................. 12

 

Forage Wagon Controller & Power Supply.................................................................................................. 12

 

Setting the RFID Number .............................................................................................................................. 14

 

Fitting the Power Module Circuit Board ...................................................................................................... 15

 

Fitting the Wheel Sensor ............................................................................................................................... 15

 

Fitting the Load Cells ................................................................................................................................... 16

 

Setting System Parameters ............................................................................................................................ 17

 

Checking Setup Parameters .......................................................................................................................... 21

 

Factory Parameter Settings .......................................................................................................................... 22

 

Final Check ................................................................................................................................................... 23

 

Technical Section ........................................................................................................ 24

 

Power and Charging ..................................................................................................................................... 24

 

System Display LEDs .................................................................................................................................... 25

 

System Safety Fuses ...................................................................................................................................... 26

 

Radio Frequency Device ............................................................................................................................... 26

 

Wiring Schematic .......................................................................................................................................... 27

 

Cable Descriptions ........................................................................................................................................ 29

 

Remote Display Screen Contrast................................................................................................................... 30

 

Fault Diagnosis ............................................................................................................................................. 31

 

Summary of Contents for 595-0036

Page 1: ...Mode Screen 9 Scales Screen 10 Installation Section 11 Component Layout 11 Remote Display Mounting Power Supply 12 Forage Wagon Controller Power Supply 12 Setting the RFID Number 14 Fitting the Power Module Circuit Board 15 Fitting the Wheel Sensor 15 Fitting the Load Cells 16 Setting System Parameters 17 Checking Setup Parameters 21 Factory Parameter Settings 22 Final Check 23 Technical Section 2...

Page 2: ...he 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 ...

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

Page 4: ...egin 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 w...

Page 5: ...holding the GO button on the controller for 1 or more seconds After establishing communication it will proceed directly to the next screen Once communication has begun between the devices a screen similar to the one below will show The modes that are available are dependant on the hardware options fitted to the machine The battery symbol indicates when the system is operating on its own battery Th...

Page 6: ... tractor this will be the internal battery voltage and connectivity status Operating Notes 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 FEED RATE 50 DISPENSED 1050kg GROSS 2950kg STOP Std 12 5V FEED RATE 50 STOP Std Ra...

Page 7: ...ge available to the unit When disconnected from the tractor this will be the internal battery voltage and connectivity status Operating Notes 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 FEED RATE 50 TO FEED 560kg GROS...

Page 8: ...TOP Dist 12 5V Mode of operation System status Feed to dispense Distance to travel Product weight in machine Connectivity status Battery voltage System battery indicator 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 T...

Page 9: ...s pressed without the wagon being plugged into the tractor and or power not getting from the tractor to the Controller FEED RATE 50 STOP Speed FEED RATE 50 DISPENSED 940kg GROSS 3540kg STOP Speed 12 5V Rate control only Rate control and load cells fitted Feed Rate System status Mode of operation Connectivity status Dispensed amount Product weight in machine Battery voltage System battery indicator...

Page 10: ...vailable to the unit When disconnected from the tractor this will be the internal battery voltage and connectivity status Operating Notes Screen Warnings None TO FEED 560kg DISPENSED 733kg GROSS 3440kg STOP Scales 12 5V Mode of operation System status Target weight to feed Dispensed amount Amount in machine Connectivity status Battery voltage System battery indicator The operator can adjust the we...

Page 11: ...2DISP Valve assembly HYSUPERVC DPBM Power module TCS V2PB Cable from switch to tractor plug 2m Controller power cable 1m TCS V2CABCON Battery TCS BATTERY2 7 core cable 5 5m with plug TCS LOOM2 Cab switch 12 24VDC Supply Tractor battery Brown Positive Blue Negative 5A Fuse Battery cable 0 55m TCS V2CABBAT Controller TCS V2CONTR Cable from battery to switch 5m 5A Fuse Tail lights 7 pin plug PLUG7PIN...

Page 12: ...pply 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 ba...

Page 13: ...e 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 Weight Module Power Module Battery base plate Run power cables this side Run load cell cables this side ...

Page 14: ...r 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 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 s...

Page 15: ...e 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 ...

Page 16: ...the wiring through the pipe brackets provided through to the junction box taking care to keep the wiring tidy and away from moving objects 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...

Page 17: ... 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 The operator can press UP or DOWN to adjust this 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 The operator can press UP or DOWN to adjust this valu...

Page 18: ... the elevator load sensing pressure Reduce this value if the elevator stalls too often Ideally this should be set approximately 200 300 PSI below tractor relief pressure The operator can press UP or DOWN to adjust this 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 The operator...

Page 19: ...ve is fitted or not and displays appropriate modes to suit The operator can press UP or DOWN to adjust this 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 The operator can press UP or DOWN to adjust this value Press MODE to continue Valv...

Page 20: ...ts of 1km h Any speed over this parameter will cause the machine to run at the percentage setting on the display The operator can press UP or DOWN to adjust this 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 machine must be moving above the minimum speed before it begins its usual function...

Page 21: ...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 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 VAL...

Page 22: ...Parameter Value Scale Damping Value 6 00 Load Cell Type 5000 00 kg Number Of Load Cells 4 00 Load Cell Sens 2 00 mV V PT or 2 20mV V Kelba 2 00mV V PT Scale Hysteresis 10 00 kg Scale Increments 10 00 kg Wheel Sensor Fitted Yes Wheel Diameter 760 00 mm No of Wheel Holes 15 00 or 23 check Low Batt Level 11 50 V Valve Fitted Yes Max Valve PSI 2250 00 psi Min Valve Setting 30 00 Valve Ramp Up Time 0 0...

Page 23: ...orking 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 rech...

Page 24: ...urs 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 ...

Page 25: ...t 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 illumi...

Page 26: ...arly 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 Lo...

Page 27: ...Generation II RF Control System Operating Installation Technical Manual RF Gen II System Technical Manual Rev02_12_10 27 Wiring Schematic For schematic check the sticker on the lid of weight module ...

Page 28: ...Generation II RF Control System Operating Installation Technical Manual RF Gen II System Technical Manual Rev02_12_10 28 Wiring Schematic V2 ...

Page 29: ... 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 Positiv...

Page 30: ... 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 7 12 07 3 8 First release of Generation ...

Page 31: ... Controller and Remote Display are operating on different channels Change both units to the same channel and re power Scale reading fluctuates Low battery voltage Check wiring from tractor and fuse in power module Loose or faulty load cell wiring Check load cell wiring Load cell cables getting interference from power cables Separate load cell and power cables Floor won t move forward when in Stand...

Page 32: ...Generation II RF Control System Operating Installation Technical Manual RF Gen II System Technical Manual Rev02_12_10 32 Troubleshooting Chart ...

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