ROJ PCS W1 Installation, Operation And Maintenance Manual Download

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PCS W1

Installation

Operation

Maintenance

ORIGINAL INSTRUCTIONS

Summary of Contents for PCS W1

Page 1: ...PCS W1 Installation Operation Maintenance ORIGINAL INSTRUCTIONS ...

Page 2: ...ange at any time the contents of this manual without notice For any technical or commercial problem please contact your local ROJ dealer or call directly ROJ customer service center We will be glad to meet your needs Thank you for your trust and good job The PCS W1 Kit is patent covered and implements unique and highly technological solutions ...

Page 3: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL Edition October 2018 Revision 1 6 Direction and Plant ROJ Via Vercellone 11 13900 Biella BI Tel 39 015 84 80 111 Fax 39 015 84 80 209 Email comm roj com www roj it ...

Page 4: ... 1 4 1 Design Criteria 1 6 1 4 2 Safety Devices and Solutions 1 7 1 4 3 Warning About Residual Risks 1 8 1 4 4 Warning and Rules of Behaviour for the Operator 1 8 1 4 5 Noise Levels 1 9 1 4 6 Radio frequency related information 1 9 1 4 7 Proper and Improper Use 1 9 1 4 8 Safety and reliability of control systems 1 10 2 INSTALLATION 2 1 2 1 GEARED MOTOR CHARACTERISTICS PCS MD O 2 1 2 1 1 Outlet sha...

Page 5: ...ettings 3 4 3 3 3 Alarm List 3 6 3 4 CONFIGURATION PAGE 3 7 3 4 1 Software Update 3 8 3 5 ALARMS 3 9 4 MAINTENANCE AND TROUBLESHOOTING 4 1 4 1 GENERAL INSTRUCTIONS ABOUT MAINTENANCE WORKS 4 1 4 2 ORDINARY PREVENTIVE MAINTENANCE INTERVENTIONS IN CHARGE OF THE OPERATOR 4 1 4 3 MAINTENANCE REPAIR RESERVED TO SPECIALIZED PERSONNEL 4 2 4 4 SPARE PARTS 4 3 INDEX UPDATES 04 07 2016 Rev 1 1 20 12 2017 Rev...

Page 6: ...er 3 The ROJ User and Maintenance Manuals contain the information deemed important and necessary by the Manufacturer in order to Understand the principle of operation of the machine 1 Carry out the handling assembly installation connection operations under Safety Condition taking into account the possible hazards connected with the above mentioned activities and providing the indications prescript...

Page 7: ...on defined by the harmonized standard EN ISO 14982 2009 for industrial environments The ROJ User and Maintenance Manuals contain the updated list of the harmonized standards applied during the design stage to guarantee the compliance with the Essential Safety Requirement Listed on Annex I of 2006 42 EC Directive while the design and implementation details are described on the Technical File kept b...

Page 8: ...012 EN ISO 4254 1 2015 EN 14018 2010 EN ISO 14982 2009 The equipment complies with the requirements of the following additional directives 2014 30 UE Directive Note 1 relating to Electromagnetic Compatibility 2014 53 EU relating to Radio Equipment Directive The person authorized to collect the Technical File is Ing Luca Bagatin luca bagatin roj com The EHSRs Essential Health and Safety Requirement...

Page 9: ...tem components If after a careful evaluation the validity of the complaint is recognized ROJ may at its sole discretion replace or repair the defective parts Other warranty terms ROJ guarantees the quality and reliability of the equipment that has been designed and manufactured to provide optimal performance The warranty does not cover any damages or indirect costs due to machine downtime or irreg...

Page 10: ...nd connect the system components in safety conditions Configure the system and program the various operation parameters according to the end user needs Perform ordinary preventive maintenance of the system in safety conditions 1 1 3 How to Use this Manual The manual is subdivided into four sections Section 1 explains the structure and the system components and contains the notes and warnings for s...

Page 11: ...Union and to those countries where a separate collection of waste is in force This symbol shown on the product or on packaging indicates that the product itself shall not be considered as normal house waste but rather that it must be delivered to an appropriate collection point for recycling of electrical and electronic equipment Making sure that this product will be correctly disposed of you will...

Page 12: ... quantity estimation in or 1 2 2 Functional blocks Ref Fig 1 1 The system consists of the following functional blocks MD one motor with integrated drive used for driving the fertilizer and micro granular distribution device AP a wi fi module which that allows the connection to the system with a smartphone table creating a dedicated wi fi network Machine position sensor to determine if the Seed Dri...

Page 13: ...ntial Health and Safety Requirement of Annex I of Machinery Directive PL Performance Level level of reliability of the safety functions according to EN 13849 1 AD Analog Digital Converter CAN Controller Area Network BUS AP Access point MD Motor with integrated drive ...

Page 14: ... AP Rugged access point module Rated voltage 12 24 VDC Rated current 250 mA 3 Machine position Machine position sensor implement switch 4 Speed sensor Hall effect speed wheel sensor 5 ISO 11786 cable Alternative to 3 and 4 can be used to receive speed and hitch position information directly from tractor 6 Wiring Wiring for connection of the various devices and to receive power from ISO 12369 plug ...

Page 15: ...z EN 62311 2008 Identical IEC 62311 2007 62368 1 2014 Audio video information and communication technology equipment Part 1 Safety requirements The compliance with the applicable paragraphs of the above listed standards allowed us to eliminate or reduce risks in the best possible way during normal operation and during maintenance and or adjustment tasks for the entire life cycle of the machine All...

Page 16: ... is not foreseen for the fertilizers and micro granular distribution units since the guard open condition does not involve exposure to hazards for the operator Access to components of the integrated drive inside the gearmotor can be carried out only using suitable tools and can be exclusively carried out by skilled and authorized staff with machine stationary and disconnected from power sources An...

Page 17: ...ur listed below ROJ will assume no liability for possible damage to people and or properties deriving from non observance of these warnings Operators shall be properly trained to use the equipment without risk and must have read and understood the instructions and warnings given in this manual Personnel performing installation and maintenance of the machine must read this manual before performing ...

Page 18: ...troduced by the PCS W1 system gearmotors are negligible 70 dBA with respect to the noise produced by agricultural machine as a whole the determination of the weighted sound pressure level generated by the whole machine is the responsibility of the manufacturer of the machine itself and or of the end user 1 4 6 Radio frequency related information The PCS W1 contains a wireless CAN to WiFi module th...

Page 19: ...s of Category and of Performance Level PL implemented with respect to the Required Performance Level PLr resulting from the risk assessment The PL calculation has been carried out by means of the SISTEMA IFA software Safety function Category PL PLr Inhibition of dangerous movements in case of metering unit guard open 1 c c The calculation of the PL values and the SISTEMA relevant report can be fou...

Page 20: ...the geared motor outlet shaft slow shaft Nominal torque 8 75Nm Peak torque 19Nm single pulse duration 500ms 12Nm repeated duration 500ms every 5 seconds Nominal speed 100 rpm The application must have the torque and speed requirements compliant with such indications For more information please refer to TD_1406 601_revD pdf or later revision 2 1 2 Outlet shaft dimensions The geared motor outlet has...

Page 21: ...e absence of a perfect alignment radial forces may occur on the bearings causing an increase of the necessary torques and a reduction of the device life In order to relieve the bearing stress an elastic coupling can be used This one is not supplied with the motor kit and it must be chosen and dimensioned according to the application 2 2 2 Mounting angle limits The gearbox must operate with the axi...

Page 22: ...oved only during the installation stage Figure 2 3 Cap with vent 2 2 4 Fastening Six special aluminium bushes are provided for the correct motor fastening The motor must be fastened to the flange using the bushes bolts M8x80 and standard M8 washers as indicated on the following figure It is suggested to lock the bolts with a thread lock product Tightening torque 10 Nm Figure 2 4 Details for the mo...

Page 23: ...toothed weel to have at least 25 pulses per revolution The sensor must be connected to the wiring connector indicated with SPEED Figure 2 5 Speed sensor and relevant cable The phonic wheel is not provided with the kit because the maximum dimensions as well as the number and shape of the teeth and the connection to the wheel depend on the type of machine and on the available space The following fig...

Page 24: ...r turn of the sensor wheel this generate 1191 pulses in 100 meter This is a good resolution 2 3 2 Tractor speed Is possible to use the speed and machine signals from the tractor with special cable 05R01423 directly connected to ISO tractor plug This connection allow tree different signal from the tractor Speed RADAR A RADAR on the tractor or RADAR emulation from the GPS Speed IN B Directly from co...

Page 25: ... e with machine lowered the sensor is de activated in transfer position i e with machine raised the sensor is activated The sensor must be connected to the wiring connector indicated with PROXY_MACHINE During the machine overall operation check you can confirm the correct operation carrying out the following procedure ...

Page 26: ...POSITIONING The housing of the AP control unit must preferably be installed in a sheltered position of the machine with cable output facing downwards Figure 2 8 AP positioning Connector must be connected to the faceplate in order to avoid the entry of water and dust The box contains the WiFi module and antenna Install the box so that the flat back surface has a 30mm clearance from metal parts Viol...

Page 27: ...Installation 2 8 PCS W1 Kit 2 6 ELECTRICAL CONNECTION DIAGRAM Figure 2 9 System connection diagram Codes of the various items are indicated on the following pages ...

Page 28: ...CS MD O W1 54T00991R PCS W1 AP 05R01422 MACHINE POSITION SENSOR 05R01400 GS102301 SPEED SENSOR CABLE L 2000mm 50A00174R HALL EFFECT SPEED SENSOR GS102301 NUT 05R01435 MD CABLE PCS W1 6 POLES 05R01423 SIGNAL CABLE ISO11786 DMD 2 6 2 MD connection Figure 2 10 MD connection diagram ...

Page 29: ... SICK RE11 SA03 or equivalent In order to ensure the requested safety level Performance Level c see paragraph 1 4 7 it is necessary to provide a safety contact with the following characteristics B10d 2 x 10e6 see note below The safety switch is not provided with the kit because the choice depends on the size limits of the machine on which it will be installed Note B10d is the reliability parameter...

Page 30: ...able the following optional cable can be ordered which can be used to connected directly to battery to create an extension and includes the protection fuse Code Description 05R01412 CAVO BAT ISO12369 2 6 5 Fuse on 05R01435 cable To fulfil the safety norms the cable 05R01435 includes a protection fuse ATO 1A black This fuse protects the supply of the access point AP and the supply to the sensors ...

Page 31: ...t using a WiFi connection 3 2 CONNECTION TO ACCESS POINT In order to connect the portable device to module turn on the WiFi interface and scan the network the module present itself as an Access Point with default SSID ROJDMDWIFI and default password is rojdmdwifi The default SSID and Password can be changed from the Configuration page see chapter 3 4 When the connection is up launch the app on you...

Page 32: ...User Manual 3 2 PCS W1 Kit Led Orange To start with the application functionality press chain button in the center of Main page In this condition led orange turn on ...

Page 33: ... PAGE The picture below shows the main web app page In the following paragraph the different functions will be described Note that the appearance of the main screen can differ depending on the motor SW version See chapter 5 0 for details ...

Page 34: ...nnection Lost 2 CAN bus connection status CAN Connection Lost or disconnected If pressed connects the AP to the motor blinking CAN Connection Poor CAN Connection OK If pressed disconnects the AP from the motor 3 Link to the configuration page press on this icon to open the configuration page Note to connect to the AP to the motor press the CAN press the button When can connection is active the yel...

Page 35: ...User Manual PCS W1 Kit 3 5 3 3 2 Job information and settings 1 2 3 5 4 7 9 10 11 6 8 12 ...

Page 36: ...t Stop Job Starts a new job and resets all counters Stops and stores job counters 6 Job list Opens job window see chapter3 8 7 Rotation1 grayed steady icon motor is NOT rotating red rotating icon motor is rotating 8 Density Range 0 2 2 kg dm3 Product density per hectare configurable by the user 9 Quantity Range 1 1000 kg ha Product quantity per hectare Configurable by the user 1 This icon is not a...

Page 37: ... starts OK Prefill on going OK Normal working status Manually excluded Error 12 Error button No error active Alarm active If pressed opens the alarm list see chapter 3 3 3 Note that the hopper will distribute the product even if the button hasn t been pressed The and buttons control the start and the end of the job recording that will be stored in the job log see chapter 3 7 ...

Page 38: ...ser of the error situation Pressing OK will acknowledge the situation and close the pop up Note that if the error situation persists the error will remain active and will be shown in the Error icon If Alarm are present and the Alarm button is pressed an alarm list section is opened as shown in the picture below ...

Page 39: ...User Manual PCS W1 Kit 3 9 Field Function Description 1 Alarm List table Table containing all active alarm together with a suggested solution 1 ...

Page 40: ... 3 10 PCS W1 Kit 3 4 CONFIGURATION PAGE The configuration page can be entered by pressing the button It contains a number of field used to configure the behaviour of the system 2 4 5 3 6 1 8 7 9 10 11 12 13 14 15 ...

Page 41: ... value selected for Prefill speed see below item 9 e g if Prefill speed value is chosen to be 5km h than by selecting Simulated the PCS W1 will simulate a working speed of 5km h This feature is useful in case of faulty speed sensors to be able to continue to work Note that if Simulated is chosen at power on is necessary to lift the machine in transport position and put it back to working position ...

Page 42: ...multiplied example and external reduction 3 2 1 is added after the motor gear the resulting gear ratio will be 3 2 x 29 71 95 07 9507 9 Prefill speed The prefill speed determines the speed at which the motor turns during the prefill during calibration and in case of simulated speed see 4 Select a value which is close to the working speed of the tractor during the job e g if the tractor at cruise s...

Page 43: ...y see Chapter 3 9 13 Network name New name SSID for the wifi created by the PCS W1 AP 14 password New password for the Network 15 Software update menu Allows to update Access Point and MD firmware Note that there is no means to reset the factory setting for the Network name and password consequently be careful to take note of the new password when changing it otherwise will not be possible to ente...

Page 44: ...CS W1 Kit 3 5 Pulse 100 calibration Once the start button is pressed the user shall travel 100m and then stop During the travelling the wheel sensor will count the pulses and provide the correct number of pulses per 100m ...

Page 45: ...ll be large enough to contain 5 10kg of product Once the container is filled the user can stop the rotation and insert the weight the amount of product in the container The app will automatically calculate the capacity per revolution of the metering wheel Note that the calibration procedure is stopped automatically after 60s if the user doesn t stop it before ...

Page 46: ...the tractor has been moving at Prefill Speed independently from the actual tractor speed i e signal from speed sensor The motor will then start to follow the tractor speed after the Prefill time is expired Figure 1 Prefill function Note that the prefill option is enabled in the following ways 1 at the first power up 2 when the following sequence is repeated at each end of the field Rotation is man...

Page 47: ...ed by Prefill Speed and Prefill Time 3 8 Job List The Jobs window allows to keep track of jobs Each job correspond to a line on the table which shows the summary of the job The following information are stored Start date Stop date Area covered Total estimated weight of distributed product ...

Page 48: ...l them when necessary The calibration relevant parameters are Capacity per turn Density of product Quantity of distributed product Prefill speed Field Function Description 1 Back If pressed go back to the main page 2 button Adds a new row with the current settings The operator is required to enter the name of the product name of the settings 1 3 2 ...

Page 49: ...t delete calibrations Select Selecting the line will open a windows with the summary of the relevant parameters that will be set Pressing Apply will load the selected settings into the PCS W1 Delete swiping a row will allow to delete it ...

Page 50: ...r shaft i e after the whole gearbox chain as specified in the Gearbox Ratio field 3 Play Stop button Start stop the motor When started the motor will run at the set point speed If the specified motor speed is higher than nominal the motor will self limit itself to the maximum possible in the working conditions 4 Error button Same as the one in main page See chapter 3 3 1 item 12 5 Motor Speed Actu...

Page 51: ...1 Kit 3 21 6 Torque Motor torque as of its nominal E g 50 indicates that the motor is working at half its nominal torque 7 Battery voltage Voltage measured at motor input V 8 LCF Linear conversion factor debug parameter ...

Page 52: ...ibutor Check distributor of stuck blocking product 32 High voltage Check battery connection and fuses 64 Low voltage Check battery connection and fuses 128 Low voltage warning Check battery connection and fuses 256 PCB high temperature Let motor cool down Check mechanical arrangement to check that there aren t unwanted frictions damage bearings etc 1024 Motor lock Let motor cool down Check mechani...

Page 53: ...he version of the app at the date of release of this manual is 1 1 2 The following functions are conditioned on the SW versions Motor rotation icon in main screen In case this function is not available the icon is not shown on the home screen Prefill mode selector In case this function is not available the selector is not shown and the prefill mode will be normal 0 01 accuracy of hectare counter I...

Page 54: ...te 2 skip the instruction pages a If you reach the following page then you have a first generation of PCS W1 b If you reach the following page then you can determine the version on the lines PCS W1 versions and MD versions 5 2 Compatibility table The following table summarizes which features are available on the PCS W1 depending on the SW versions you own see 5 1 ...

Page 55: ...unter accuracy First generation 1 1 A 2 2 X 0 0 A 2 2 A 2 6 Note that first generation PCS W1 versions or the one with MD version X 0 can t be upgraded to support the features indicated above The other versions can be upgraded to support all features Please contact your local dealer of ROJ s customer service mechatronics roj com for further details ...

Page 56: ...em Prior to start the maintenance works thoroughly clean the relevant zone Do not use solvents All environmental impact materials that is necessary to eliminate as a result of maintenance operations such as lubricants dirty clothes filter elements must be disposed of according to applicable regulations Make sure that unauthorized personnel CANNOT have access to the working area during the maintena...

Page 57: ...can be done by activating the motors and verifying that when opening the safety contact of each MD the motor stop its movement 4 4 PARAMETER RANGE PCSW1 Range Units Commercial name Min Max 10000 10000 Gear ratio 800 500000 Pulse 100m 20 800 cm Machine Width 0 2 2 kg dm Density 1 1000 kg ha Quantity 0 01 4000 cm turn Capacity 0 20 sec Prefill Time 0 036 32 4 km h Prefill Speed 0 100 rpm Speed set p...

Page 58: ...gure 4 1 Spare part chart Code Description 1406 603 PCS MD O 54T00991R PCS W1 AP 05R01422 MACHINE POSITION SENSOR 05R01400 GS102301 SPEED SENSOR CABLE L 2000mm 50A00174R HALL EFFECT SPEED SENSOR GS102301 NUT 05R01435 MD CABLE PCS W1 05R01423 SIGNAL CABLE ISO11786 DMD ...

Page 59: ...Maintenance and Troubleshooting 4 4 PCS W1 Kit Page intentionally left blank ...

Page 60: ...Vercellone 11 13900 Biella BI Tel 39 015 84 80 111 Fax 39 015 84 80 209 Email comm roj com www roj it REV 1 6 E 10 2018 ISO 9001 Certificates by DNV from 1996 ISO 9001 2008 Certificates in 2009 DISTRIBUTOR ...

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