Ag Leader Technology. DirectCommand Installation Hardi 20-pin Interface Kit (Sprayer Chassis Mount)

Transcription

1 Part Name / Description Part Number Quantity DirectCommand Hardi Sprayer Kit Dust Receptacle 8-pin C 1 Installation Instructions Quick Reference Card- Liquid Application Dielectric Grease Y-Splice Terminator Liquid Product Control Module CAN Bus Stub 8 in Implement Plug CAN/Power Cable 3 ft Implement Cable 12 ft Boom Valve Relay Module Boom Valve Relay Module Cable Power/Polarity Reversing Relay Cable Main On/Off Valve Adapter 1 ft Hardi 20-Pin Adapter Cable Hardi Radar Cable BVRM 1 Adapter Cable BVRM 2 Adapter Cable Cable Installation Kit Hardware Kit Large Module Mounting Plate Dual Module U-Bolt 5/16 x 2-11/16 in Hardware Kit RAM Rail Mount Kit 5 Arm RAM 201U 5 Arm RAM 2461U Display Mount RAM 235U Base, Double U-Bolt Items Purchased Separately: (This Kit Will Require One Of The Switchboxes Below) CAN Switch Box Kit Switch Console Mounting Bracket Hardware Kit Switch Console Switch Console Model SC Y-Splice CAN Bus Plug Optional Items Necessary To Mount Three Control Modules (Purchase Separately) Hardware Kit Large Module Mounting Plate DirectCommand 3 Module Boom Valve Relay Module PN: Rev D January 2014 Page 1 of 20

2 Contents Important Notices Heading Page Common Components 3 Component and Cable Layout 4-5 Safety Notices 6 Installing the Display 7 Installing the Power and Cab Cables 9 Installing the Control Modules 11 Installing the Power/CAN Bus Cables 15 Configuring the Hardi Adapter Cable 16 Installing the Rate Control Cables 17 Setting up the Display 20 You will save time and prevent wrong installation of components by closely following these step-by-step instructions. If you have questions, call Ag Leader at x 1. Direction words (LEFT and RIGHT) are commonly used when describing an installation procedure. Interpret direction words as if standing behind equipment and looking forward. Signal words (CAUTION, IMPORTANT and NOTE) are provided to draw attention to information that is important for the safe/correct installation and operation of this product. CAUTION will alert you to situations that will impact the physical safety of you or others. IMPORTANT will alert you to the potential for damage to the product or loss of data. NOTE will provide you with additional information to simplify a procedure or clarify a process. Read all instructions first to familiarize yourself with the installation procedures. Keep parts list and Installation Instructions for use as a reference after completing installation. This DirectCommand kit will fit the following equipment: Hardi 20-Pin sprayer interface using Ag Leader Control Modules mounted on the sprayer chassis. If the sprayer is equipped with more than five boom sections you will need to install an additional Boom Valve Relay Module PN: This additional Boom Valve Relay Module is not included in this kit. Page 2 of 20 January 2014 PN: Rev D

3 Common Components This section contains illustrations of components common to DirectCommand installations. Their purpose is to ensure proper identification and installation in the sections that follow. Brown Seal Blue Seal CAN Bus connectors 1.Terminator PN: Dust Plug PN: Not all applications 3.Y Splice PN: Boom Valve Relay Module 2. Liquid Product Control Module 3. Optional Boom Valve Relay Module (>5 s) PN: Rev D January 2014 Page 3 of 20

4 Component and Cable Layout- CAN Switchbox Page 4 of 20 January 2014 PN: Rev D

5 Component and Cable Layout- Standard Switchbox PN: Rev D January 2014 Page 5 of 20

6 Safety Notices CAUTION: Sprayer booms should be lowered to ground or on mechanical safety stops before starting work. Do not work under sprayer booms supported by hydraulic system only. Turn off sprayer and tractor and wait for all machine motion to stop before starting work. Set parking brake. CAUTION: Be sure to wear proper eye protection when using any power tools, such as when drilling any mounting holes. IMPORTANT: Check behind vehicle and implement panels for any hoses, wiring, controls, etc. that could be damaged when drilling any mounting holes. IMPORTANT: Disconnect the Display, DirectCommand components and flow meter from electrical system when welding on equipment or jump starting unit to prevent component damage due to power surges or excessive current IMPORTANT: If using a non Ag Leader GPS receiver make sure to install the Null Modem Cable PN: , included in the Display kit, to prevent damage to the Display or the GPS receiver. IMPORTANT: Use the Dielectric grease to coat the seals and terminals of each connector that will be exposed to weather or chemicals as you plug them in. NOTE: Be sure to follow the alignment keys on the plugs and the receptacles carefully. Do not use excessive force when mating connectors. Page 6 of 20 January 2014 PN: Rev D

7 Installing the Display Parts required for procedure: (1) Ag Leader INTEGRA Display Or (1) EDGE Display Or (1) InSight Display PN: PN: PN: From the CAN Switchbox Kit: (1) Switch Console Bracket PN: (1) Switch Console PN: Or From the Standard Switchbox Kit: (1) Switch Console Bracket PN: (1) Switch Console PN: From the RAM Rail Mount Kit: (1) RAM 201U 5 Arm PN: (1) RAM 2461U Display Mount PN: (1) RAM 235U Base, Double U-Bolt PN: From Display Kit or Display Cable Kit : (1) Power Control Relay PN: (1) Display Cable PN: Step by step instructions for mounting the Switch Console to the Display 1. Place the Display face down on a stable surface. Align one hole of the Switch Console Bracket PN: and Display Mounting PN: with a threaded hole in the Display. Start one 6mm Phillips head screw with lock washer. 2. Align the other three holes and start another three 6mm Phillips head screws with lock washers, tighten all four screws securely. See figure Align the two threaded holes in the Switch Console with the two holes in the Switch Console Bracket. Start two 6mm Phillips head screws with lock washers and tighten the screws securely. See figure 2. PN: Rev D January 2014 Page 7 of 20

8 Figure 1 Display with Switch Console And RAM Display Mount Step-by-step instructions for installing the Display 1. Turn on the existing rate control console, if equipped with one, and copy down the boom section widths and flow meter calibration numbers. 2. Run the sprayer one last time to make sure all of the components are in working order before removing the console. Verifying that all of the rate control components work will help with any potential troubleshooting issues after the installation. 3. Turn off the existing rate control console, if equipped with one, and disconnect the cables from the console and remove the console from the sprayer. 4. Remove the Hardi Scan Box, 2500 series controller, and all cables connected to them except the ground speed sensor, flow meter and the main Hardi 20 pin connector cables. NOTE: If the RAM Base - Double U-bolt rail mount will not work for this installation you can order an optional RAM base mount from your Ag Leader Dealer. 5. Take the RAM Base, Double U-bolt PN: from the RAM rail mount kit. Use the two U-bolts, nuts and washers to fasten the mount on the rail where the console was previously mounted. 6. Mount the Display, using the RAM 201U 5 Arm PN: , in a convenient place in the cab for operation, but out of the operator s line of sight while driving. 7. Connect the round 28-pin connector on the Display Cable, PN: , to the connector on the back of the InSight or EDGE Display, or the connector labeled MAIN on the back of the Ag Leader INTEGRA Display. Page 8 of 20 January 2014 PN: Rev D

9 8. Connect the Power Control Relay, PN to the Display Cable at the black 4-pin Weatherpack connector. Press together until the latch clicks, locking the relay together with the Display Cable. Installing the Power and Cab Cables Parts Required for Procedure: From DirectCommand Kit: (1) Cable Radar (Hardi 20 Pin System) 4ft. PN: (1) Cable CAN/Power Implement Connection PN: (1) Cable- Power- Guidance/High Current 12ft. PN: (1) Cable Installation Kit PN: From CAN Switch Box Kit: (1) CAN Y-Splice PN: From the Standard Switchbox Kit (If Applicable): (1) CAN Bus Stub 1 ft. PN: (1) Auxiliary Input Module PN: Step-by-Step instructions for installing the Power and Cab Cables IMPORTANT: Disconnect the battery ground cable. By not disconnecting the ground cable damage could be done to machine components. Note: If using the Standard Switch Box Kit, PN: mount the Auxiliary Input Module in the vehicle cab within reach of the CAN Bus Stub, PN: Connect the ring-terminated ends of the Power Cable PN: directly to the battery cable. The fused wires go to the positive side and the black wires go to the negative side. Refer to figure 3, on the next page, for different battery configurations and follow the notations for Ag Leader Power and Ag Leader Ground. 2. Find a suitable opening in the floor or the rear window area of the cab to route the opposite end of the Power Cable into the cab. PN: Rev D January 2014 Page 9 of 20

10 Figure 2 3. Connect the 3-pin Weather Pack plug on the Power Cable to the 3-pin Weather Pack receptacle of the Display Cable, PN: Locate the CAN/Power Cable, PN: in the DirectCommand Kit. 5. Connect the gray 2-pin Deutsch power receptacle from the CAN/Power Cable to the mating gray 2-pin plug on the Power Cable, PN: Locate the CAN Y-Splice, PN: in the appropriate Switch Box Kit, PN: or NOTE: To properly connect the CAN Bus terminals firmly pinch the metal clip against the plastic connection and then connect and disconnect the CAN Bus terminals as needed. Page 10 of 20 January 2014 PN: Rev D

11 7. Connect the single end of the CAN Y-Splice to the mating connector on the Display Cable, PN: Connect the 4-pin Cannon Plug from the CAN/Power Cable, PN: into the black side of the CAN Y-Splice. The Below Instructions Are For A Standard Switch Box Kit, If using a CAN Switch Box Skip To Step If using the Standard Switch Box Kit locate the CAN Bus Stub, PN: and connect the 4-pin Deutsch plug to the mating receptacle labeled CAN BUS on the Auxiliary Input Module. 10. Connect the 4-pin Cannon Plug from the opposite end of the CAN Bus Stub to the mating connection of the gray side of the CAN Y-Splice. 11. Locate the cable coming from the Standard Switchbox and connect the green and brown Deutsch 12-pin plugs to the mating connectors on the Auxiliary Module labeled SWITCH A and SWITCH B. 12. Connect the 4-pin Cannon Plug from the CAN Switch Box Cable, PN: into the gray side of the CAN Y-Splice. 13. Connect the gray 6-pin Deutsch plug of the Hardi Radar Cable PN: to the mating gray 6-pin Deutsch receptacle on the CAN Switch Box Cable or Auxiliary Input Module. 14. Route the opposite end of the Hardi Radar Cable with the green 3-pin Phoenix connector out of a suitable opening in the rear cab area. 15. Route the opposite end of the CAN/Power Cable, PN: , with the 16-pin Amp CPC plug, out of the same opening in the rear cab area. 16. Bundle cables and secure them as necessary with cable ties from the Cable Installation Kit, PN: Installing the Control Modules Parts required for procedure: From the DirectCommand Kit: (1) Liquid Product Control Module PN: (1) Boom Valve Relay Module PN: (1) Mounting Plate Dual Module PN: (1) U-Bolt 5/16 in. x 2-11/16 in. PN: Hardware Kit 6 PN: (1) Hardware Kit Large Module PN: PN: Rev D January 2014 Page 11 of 20

12 Optional Items necessary to install a second BVRM: (Purchase Separately) (1) Hardware Kit Large Module PN: (1) Mounting Plate DirectCommand PN: (1) Boom Valve Relay Module PN: Step by step instructions for installing the Control Modules NOTE: Configurations with greater than 5 boom sections will require a second Boom Valve Relay Module purchased separately. NOTE: This DirectCommand Kit supports many model years of the Hardi sprayer. Some deviation from the below instructions may be necessary depending on the model year of your sprayer. Installation of one Boom Valve Relay Module & LPCM. If your application requires two BVRM s go to step 8: 1. Locate the Mounting Plate Dual Module, PN: in the DirectCommand Kit. 2. Locate the Liquid Product Control Module, PN: and Boom Valve Relay Module, PN: in the DirectCommand Kit. 3. Find a suitable location on the sprayer to secure the Mounting plate within reach of the Hardi 20-pin connector on the Hardi sprayer harness. 4. Using a 5/16 in. bit, drill two holes 2 in. center to center on the Dual Module Mounting Plate to use later for mounting the plate the sprayer. (Refer to the figure below) New Mounting Hole Locations On The Mounting Plate PN: Page 12 of 20 January 2014 PN: Rev D

13 5. Mount the Liquid Product Control Module and Boom Valve Relay Module on the Dual Module Mounting Plate, PN: using the ¼ in. hardware provided in the Hardware Kit, PN: to the secure the modules. 6. Locate the 5/16 in. x 2-11/16 in. U-bolt, PN: , 5/16 in. Hex Nylock Nuts and 5/16 in. Flat Washers PN: in the DirectCommand Kit. 7. Using the items located in the previous step mount the Dual Module Mounting Plate, PN: to a square tube, round bar or other appropriate surface on the sprayer. Instructions for installing two Boom Valve Relay Modules & LPCM: Parts required for procedure: From the DirectCommand Kit: (1) Hardware Kit Large Module PN: (1) Liquid Product Control Module PN: (1) Boom Valve Relay Module PN: (2) U-Bolt 5/16 in. x 2-1/2 in. PN: (1) Hardware Kit 6 PN: Items purchase separately: (1) Hardware Kit Large Module PN: (1) Mounting Plate DirectCommand PN: (1) Boom Valve Relay Module PN: Locate the Mounting Plate DirectCommand, PN: , purchased separately. 9. Locate the Liquid Product Control Module, PN: and Boom Valve Relay Module, PN: in the DirectCommand Kit and the second Boom Valve Relay Module, purchased separately. 10. Find a suitable location on the sprayer to secure the Mounting plate within reach of the Hardi 20-pin connector on the Hardi sprayer harness. 11. Using a 5/16 in. bit, drill two sets of holes 2 in. center to center on the top and bottom of the DirectCommand Module Mounting Plate to use later for mounting the plate to the sprayer. (Refer to the figure on the next page) 12. Mount the Liquid Product Control Module and Boom Valve Relay Modules on the Module Mounting Plate, PN: using the ¼ in. hardware provided in the Hardware Kits, PN: to the secure the modules. PN: Rev D January 2014 Page 13 of 20

14 13. Locate the 5/16 in. x 2-11/16 in. U-bolts, PN: , 5/16 in. Hex Nylock Nuts and 5/16 in. Flat Washers PN: in the DirectCommand Kit. 14. Using the hardware from the previous step mount the Module Mounting Plate to a square tube, round bar or other appropriate surface on the sprayer. New Mounting Hole Locations On The Module Plate PN: Installing the Power/CAN Bus Cables Parts required for procedure: From the DirectCommand Kit: (1) Y-Splice PN: (1) Terminator PN: (1) CAN Bus Stub 8 in. PN: (1) Implement Cable 12ft. PN: Page 14 of 20 January 2014 PN: Rev D

15 Step by step instructions for installing the CAN Bus Cables NOTE: To properly connect the CAN connectors firmly pinch the clip against the plastic connection and then mate the ends. 1. Locate the Implement Cable, PN: in the DirectCommand Kit. 2. Connect the single end of the Y-Splice PN: to the round black CAN Bus receptacle on the Implement Cable. 3. Connect the round terminal of the CAN Bus Stub 8 in. PN: to the gray side of the Y-Splice installed in step Connect the gray 4-pin Deutsch plug of CAN Bus Stub 8 in. to the gray 4-pin receptacle marked CAN BUS on Liquid Product Control Module. 5. Connect the Terminator PN: to the black side of the Y-Splice installed in step Connect one the of the gray 2-pin Deutsch power plugs from the Implement Cable to the mating power receptacle on the Liquid Product Control Module, PN: Configuring the Hardi Adapter Cable Parts required for procedure: From the DirectCommand Kit: (1) Hardi Adapter Cable PN: (1) BVRM 1 Adapter Cable PN: (1) BVRM 2 Adapter Cable PN: Step by step instructions for configuring the Hardi Adapter Cable 1. Figure 4 shows the Hardi Adapter Cable and the BVRM 1 Adapter Cable (sections 1 thru 5) and the BVRM 2 Adapter Cable (sections 6 and 7). 2. If the sprayer has five sections or less the BVRM 2 Adapter Cable will not be used. PN: Rev D January 2014 Page 15 of 20

16 Figure 3 Hardi Adapter Cable - left BVRM 2 Adapter Cable top right BVRM 1 Adapter Cable bottom right 3. Follow the chart below to configure the Hardi Adapter Cable PN: , the BVRM 1 Adapter Cable PN: and the BVRM 2 Adapter Cable PN: , if required, for the number of boom valves and the Hardi controller previously used. 4. Make sure that the black 2-pin Weather Pack connectors seat completely and the latches are snapped shut. Leave any unused connectors on the Hardi Adapter Cable sealed with the dust plugs. Hardi Adapter Cable Connector Connector A 3 EC Controller 3 ESC/EVC/ECP/ECPC Controllers 4 Boom s 5 Boom s 6 Boom s 7 Boom s 1 Connector B Connector C Connector D Connector E Connector F Connector G 6 7 Figure 4 Page 16 of 20 January 2014 PN: Rev D

17 Installing the Rate Control Cables Step by step instructions for installing the Rate Control Cables Parts required for procedure: From the DirectCommand Kit: (1) Dust Receptacle 8-pin PN: C (1) Boom Valve Relay Module Cable PN: (1) Hardi Radar Cable PN: (1) Power/Polarity Reversing Relay Cable PN: (1) Main On/Off Valve Adapter 1ft. PN: (1) Implement Plug PN: (1) Configured Hardi Adapter Cable PN: Connect the Boom Relay Module Cable PN: by plugging the gray 12-pin Deutsch plug into the gray 12-pin Deutsch receptacle marked BOOM on the Liquid Product Control Module. 2. Connect the green 8-pin Deutsch plug marked sections 1-5 to the green 8-pin Deutsch receptacle marked BOOM IN on the number one Boom Valve Relay Module. 3. If this installation requires two Boom Valve Relay Modules skip to step four. If this installation requires only one Boom Valve Relay Module seal the green 8-pin Deutsch plug marked sections 6-10 with the Dust Receptacle 8- pin PN: C. Skip step four. 4. Connect the second green 8-pin Deutsch plug marked sections 6-10 to the green 8-pin Deutsch receptacle marked BOOM IN on the second Boom Valve Relay Module. 5. Locate the Power/Polarity Reversing Relay Cable, PN: in the DirectCommand Kit. 6. Connect the second gray 2-pin Deutsch power plug from the Implement Cable to the gray 2-pin Deutsch receptacle on the Power/Polarity Reversing Relay Cable PN: Connect the gray 2-pin Deutsch plug from Power/Polarity Reversing Relay Cable to the mating gray 2-pin Deutsch receptacle on the Boom Valve Relay Module Cable, PN: Locate the Implement Plug Cable, PN: in the DirectCommand Kit. 9. Using a small flat-blade screwdriver, remove the wedge lock from the connector and save for later installation. PN: Rev D January 2014 Page 17 of 20

18 Removing Auxiliary Connector Wedge Lock 10. Remove the white seal plugs from the Pin #7, Pin #8 and Pin #9 positions on the black 12-pin plug. 11. Insert the black wire from the Power/Polarity Reversing Cable, PN: labeled Module GND into the Pin #7 location on the black 12-pin auxiliary connector. 12. Insert the white wire from the Power/Polarity Reversing Cable, PN: labeled Aux Valve 1 into the Pin #8 location on the black 12-pin auxiliary connector. 13. Insert the green wire from the Power/Polarity Reversing Cable, PN: labeled Aux Valve 2 into the Pin #9 location on the black 12-pin auxiliary connector. 14. Replace the wedge lock removed in step Connect the black 12-pin Deutsch plug from the Implement Plug Cable PN: in the mating receptacle labeled AUXILIARY on the Liquid Product Control Module. 16. Remove the black 2-pin Deutsch Dust Plug from the Hardi Adapter Cable, PN: Connect the black 2-pin Deutsch plug from the Main On/Off Valve Adapter Cable, PN: to the black 2-pin Deutsch receptacle on the Hardi Adapter Cable. 17. Connect the gray 4-pin Deutsch receptacle on the Main On/Off Valve Adapter Cable to the mating gray 4-pin Deutsch plug on the Power/Polarity Reversing Cable, PN: Connect the green 12-pin Deutsch plug of the BVRM 1 Adapter Cable to the green 12-pin Deutsch receptacle marked BOOM OUT on the number one Boom Valve Relay Module. Page 18 of 20 January 2014 PN: Rev D

19 19. If this installation requires two Boom Valve Relay Modules, connect the green 12-pin Deutsch plug of the BVRM 2 Adapter Cable to the green 12- pin Deutsch receptacle marked BOOM OUT on the second Boom Valve Relay Module. 20. Connect the gray 8-pin Deutsch plug of the Hardi Adapter Cable, PN: to the gray 8-pin Deutsch receptacle on the Liquid Product Control Module marked CHANNEL Plug the male 20-pin connector on the Hardi Adapter Cable into the female 20-pin connector on the Hardi sprayer harness. 22. Mate the green 3-pin connector from the Hardi Adapter Cable, PN: to the green 3-pin flow meter connector on the Hardi sprayer harness. 23. Locate the green 3-pin connector from the Hardi Radar Cable PN: routed out of the rear cab area in a previous section of these installation instructions. 24. Connect the green 3-pin connector on the Hardi Radar Cable to the mating green 3-pin connector coming from the Hardi speed sensor cable. 25. Route the opposite end of the Implement Cable, PN: toward the front of the sprayer. 26. Locate the CAN/Power Cable, PN: routed out of the rear cab area in a previous section of these installation instructions. 27. Connect the black 16-pin Amp CPC plug from the CAN/Power Cable to the mating black 16-pin Amp CPC receptacle on the Implement Cable. 28. If necessary, extension cables may be purchased for additional length. Refer to the table below for available lengths. Length Part Number 6 ft ft ft ft Implement Cable Extensions 29. Secure all cables with cable ties included in the Cable Installation Kit, PN: avoid sharp edges and pinch points that could cause any cable damage. PN: Rev D January 2014 Page 19 of 20

20 30. Reconnect the battery ground. Setting up the Display 1. Refer to the Quick Reference Guide PN: for setting up the Ag Leader Display. 2. Enter the default settings for the Display from the following chart. Setting Name Default Value Valve response % Valve response 2 40 % Allowable Error 2 % Response Threshold 2 Hardi Calibrated Reflow Description Determines the speed of the servo valve when product control error exceeds the Response Threshold setting. Decreasing the value will cause the servo valve to run slower Determines the speed of the servo valve when product control error is less than the Response Threshold setting. Decreasing the value will cause the servo valve to run slower. Determines the percent of error that is allowed prior to the product control system making any flow rate corrections. 2 % 3 % is the normal dead band setting range. Too low of a setting will cause the control system to continually hunt for the target application rate. Too high of a setting will cause excessive application error. Determines where the control system switches between using Valve response 1 and Valve response 2 speed settings. Decreasing this value will have the overall effect of speeding up servo valve response. Increasing this value will have the overall effect of slowing down servo valve response. NOTE: Leaving all other valve control settings at the default value and making a small adjustment to the Response Threshold setting is usually all that is required to finetune the control system. Flow Meter Cal* Check flow meter Flowmeter Style Flow Rates InSight Settings One Outside Groove 2-30 g/min 485 No Groove 4-70 g/min 225 Two Outside Grooves g/min 475 NOTE: If the flow meter calibration number is for gallons per minute and you want to apply liters per minute you will need to convert the flow meter cal number by dividing it by the conversion factor Example: 225 / = Enter this value in the Display. *Verify that the flow meter calibration number is correct by checking your flow meter style with the Hardi set up manual NOTE: If it becomes necessary to change one of these default settings make changes to one value at a time so that changes can be evaluated accurately. Page 20 of 20 January 2014 PN: Rev D