GETTING STARTED... 2 GENERAL SETUP INSTRUCTIONS...2

Transcription

1 RF Control System Technical Manual Supplement 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 Manual Valve Over-ride Function Radio Frequency Device RIO Box Start/Reset Button Start-up Screen Standard Screen Additional Features Weight Screen Distance Screen Speed Screen Scales Screen INSTALLER CONFIGURATION INSTRUCTIONS CONTROL MODE OPTIONS UPGRADE KIT (WEIGHT & DISTANCE MODES) UPGRADE INSTALL PROCEDURE FITTING THE LOAD CELLS FITTING THE JUNCTION BOX FITTING THE SPEED SENSOR QUICK CHECK SETTINGS FINAL CHECK RADIO FREQUENCY SYSTEM FAULT DIAGNOSIS... 32

2 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 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 BLUE Tractor Positive (12-24VDC) 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 4 Wiring Schematic 12 24VDC Supply Brown (Positive) Blue (Negative) 5A Fuse Cab switch Cab mounted monitor Wheel sensor White Positive Blue - Negative Junction box Load cells (4 or 6) Scale/Wheel sensor cable Aerial RIO box Power/Amplifier cable Amplifier / Coil / Valve Assembly Brown Positive Blue - Negative Trailer lights

5 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 % % % % % % % % % % % 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 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 Speed Sensor 12V (V+) Brown Green 4 Signal (PX) Black Orange 5 Signal White White/Orange 6 Load Cells (4 or 6) Signal + Green Blue 7 Excite + Red White/Blue 2 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) Power/Amplifier Cable 7 4 Load Cell/Speed Sensor Cable 6

7 7 Trailer Plug Wiring Connection Auxiliary (RF Positive) Red or Brown Earth (RF Negative) Black & Yellow or Blue Indicator White Indicator Green or Blue Brake Light Red Tail/Park Light Yellow Spare 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 VDC (tractor engine running) and be able to supply at least 5A when the key is activated.

8 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 settings sequentially: HI, LO, UP, dn, Cd, df, di and SA. 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 LO Low 02-HI 00 UP Ramp up dn Ramp down Cd Command deadband df Dither frequency di Signal displayed 00 or Amplifier Plug Wiring E Table 6 E Blank Not used 1 Brown Positive 2 Blue Ground 3 Green/Yellow Command Signal

9 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 # Switch On None

10 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 Over-ride adjuster 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. 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 autopowered 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 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. RATE: 50% Feed Rate System status Mode of operation RF channel STOP Std 1 Connectivity status The operator can adjust the rate percentage figure. This is done by pressing or on the keypad. START STOP 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. RATE: 50% DISP: 1050kg GROSS: 2950kg STOP Std 12.5V 1 Feed Rate Dispensed amount Amount in machine Battery voltage The operator can switch to the Weight, Distance, Speed or Scales operating screens (if enabled) by pressing MODE on the keypad. The operator can zero the gross and dispensed weight by pressing keypad. on the START The operator can zero only the dispensed weight by pressing on the keypad. The operator can select between gross and tare weight to be displayed by pressing GROSS or TARE on the keypad. ZERO

12 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. Mode of operation System status RATE: 1000kg/min DISP: 560kg GROSS: 3440kg STOP Weight 12.5V 1 Feed Rate Dispensed amount Amount in machine 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. START STOP The operator can start and stop the feed-out by pressing or on the keypad. The operator can switch to the Standard, Distance, Speed or Scales operating screens by pressing MODE on the keypad. The operator can zero the gross and dispensed weight by pressing keypad. ZERO on the START The operator can zero only the dispensed weight by pressing on the keypad. The operator can select between gross and tare weight to be displayed by pressing GROSS or TARE on the keypad.

13 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. START 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. DISP: 1800kg OVER: 52m 100m GROSS: 3540kg STOP Dist 12.5V 1 Amount to dispense Distance travelled Overall distance Amount in machine 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. START STOP The operator can start or stop the feed-out by pressing or on the keypad. The operator can switch to the Standard, Weight or Speed operating screens by pressing MODE on the keypad. The operator can zero the gross and dispensed weight by pressing keypad. ZERO on the START The operator can zero only the dispensed weight by pressing on the keypad. The operator can select between gross and tare weight to be displayed by pressing GROSS or TARE on the keypad.

14 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. RATE: 12% DISP: 940kg GROSS: 3540kg STOP Speed 12.5V 1 Dispense rate Dispensed weight Weight in machine The operator can select the feed-out rate by adjusting the rate percentage figure. This is done by pressing or on the keypad. START STOP The operator can start or stop the feed-out by pressing or on the keypad. The operator can switch between Standard, Weight and Distance operating screens by pressing MODE on the keypad. The operator can zero the gross and dispensed weight by pressing keypad. ZERO on the START The operator can zero only the dispensed weight by pressing on the keypad. The operator can select between gross and tare weight to be displayed by pressing GROSS or TARE on the keypad. 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 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: GROSS: 560kg 3440kg Dispensed amount Amount in machine Scales 12.5V 1 Mode of operation ZERO The operator can zero the gross weight and dispensed weight by pressing on the keypad. START The operator can zero only the dispensed weight by pressing on the keypad. The operator can select between gross and tare weight to be displayed by pressing GROSS or TARE on the keypad. START To allow the dispensed weight to accumulate, the operator must press before commencing feeding. The operator can switch between Standard, Distance and Speed operating screens (if enabled) by pressing MODE on the keypad.

16 16 Installer Configuration Instructions Entering Configuration Screens ZERO TARE 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. MODE Press to move to the next configuration screen. ESCAPE Press to exit the configuration screens. 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. Press to accept. Forage Wagon Model Distance 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. Scale Damping Value 1.00sec 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 Press to accept. Load Cell Type kg Number of Load Cells The Number of Load Cells parameter specifies the total amount of load cells fitted to the machine. The operator can press or to adjust this value. Press to accept. Number of Load Cells 4.00 Load Cell Sensitivity

17 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. The operator can press or to adjust this value. Press to accept. Load Cell Sens. 2.00mV/V 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. Weight H/W Rev V4-41-B Scale Hysteresis The Scale Hysteresis parameter specifies how much a weight reading needs to change before the reading on the screen will change. The operator can press or to adjust this value. Press to accept. Scale Hysteresis 10.00kg Scale Increments The Scale Increments parameter specifies minimum scale increment displayed on the screen. The operator can press or to adjust this value. Press to accept. Scale Increments 10.00kg 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. Valve Min. cal cn

18 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. Valve Max. cal cn The operator can press or to adjust this value while watching the amplifier display screen. Press to accept. Wheel Diameter The Wheel Diameter setup screen is used to calibrate the distance measurement for the size if the wheel on the forage wagon. The operator can press or to adjust this value. Press to accept. Wheel Diameter mm 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. No. of Wheel Holes 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. RFID Number 1.00 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. See page 77 to change RIO box RF channel number.

19 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. The operator can press or to adjust this value. Press to accept. Low Batt Level 11.00V 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 V. Set. Dis 85.00% 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. Startup V. Set. Kg/m 85.00% 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. The operator can press or to adjust this value. Press to accept. Minimum V. Setting 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. The operator can press or to adjust this value. Press to accept. Min. F.R. kg/min kg

20 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. Speed Mode Min Speed 1.00km/h The operator can press or to adjust this value. Press to accept. 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. Speed Mode Max Speed 6.00km/h Any speed over this parameter will cause the machine to run at 100% (full speed). The operator can press or to adjust this value. Press to accept. 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. Speed Mode Strt Time 1.00sec The operator can press or to adjust this value. Press to accept. 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. Dist. Before Finish 1.00m The operator can press or to adjust this value. Press to accept.

21 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. Weight board fitted Load cells fitted Input/output board fitted

22 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. Weight board fitted Input/output board fitted Load cells fitted Wheel sensor fitted 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

23 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 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 1x 1x 1x 1x 1x Junction box for load cell wiring Strip terminal connector (to join wires if junction box is blank) Load cell/speed sensor cable (7 core) to junction box SLA (sealed lead acid) 12V, 2.3Ah battery Circuit board, part description v4-35a (input/output circuit board) Circuit board, part description v4-41b (weigh circuit board) Available separately: 1x Speed sensor with cable

24 24 Upgrade Install Procedure OPINT upgrade: ZERO TARE To enter set-up, press and together for 3 seconds or until the set-up screen appears. A screen similar to the one below should be displayed: Forage Wagon Model Standard MODE 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. ESCAPE Press to exit the configuration screens. 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 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 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 M ft/lbs or 380Nm M 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 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 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 29 Setting up a 240V 3-pin Charger System Parts Supplied 0.8A 3-pin Charger 7-pin Female Tractor Plug Trailer Plug Wiring Connection (viewed from front, looking at pins) Auxiliary (RF Positive) Red or Brown Earth (RF Negative) Black & Yellow or Blue Indicator White Indicator Green or Blue Brake Light Red Tail/Park Light Yellow Spare 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).

30 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 ZERO TARE To enter set-up, press and together for 3 seconds or until the set-up screen appears. Press until Weight, Distance (if speed sensor is fitted) or Scales is displayed. Press to accept. ESCAPE 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 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 kg Scale Increments kg Valve Min. Cal cn. Valve Max. Cal cn. Wheel Diameter mm No. of Wheel Holes RFID Number 1.00 (must match RIO Box settings) Low Batt Level 11.00V Startup V. Set. Dis % Startup V. Set. Kg/m 85.00% Min. V. Setting Min. F. R. Kg/Min kg 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 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.

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

32 32 Radio Frequency System Fault Diagnosis Problem Issue Solution Green light on RIO box won t illuminate when wagon is plugged into tractor Green light won t stay illuminated when unplugged No communication indicator ( )showing on OPINT Scale reading fluctuates Floor won t move forward while in Standard mode. Power not getting to RIO box Internal battery flat or not holding charge RIO box not active Signal interference from another machine Distance to great between RIO and OPINT Signal blocked by large object. Aerial not working correctly Low internal battery voltage Loose or faulty load cell wiring System not started Feed rate too low Faulty solenoid coil No power to unit on wagon Signal not getting to amplifier No power to unit on wagon Check fuse in RIO box Check wiring from tractor Plug wagon into tractor to recharge battery Check fuse in RIO box. Check wiring from tractor. Press green button on RIO box if fitted Change RF channel Move closer together Move away from object Check aerial for damage or incorrect position Check fuse in RIO box. Check wiring from tractor Check load cell wiring Press on keypad Increase feed rate Replace coil Check plugs and wiring Replace 36C circuit board 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) Fully configured RIO box won t hold power when tractor source Circuitry not holding power Replace input/output board 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 Check load cell wiring wiring Keypad unable to enter setup Faulty keypad Return for repair OPINT will not store settings Memory not operating correctly. correctly Possible faulty memory chip. Return for repair Incorrect weight board version in Voltage reading displays differently V2.16 software Change OPINT parameter than when voltage is tested Incorrect board positions Check if boards have been Amplifier displays 00 and won t change Amplifier is blank No communication signal incorrectly placed Check power is getting to IO box on machine OPINT not started START Press on keypad OPINT set on zero Increase feed rate Incorrect parameters Check parameters No power coming from tractor Check power is getting to IO box on machine Faulty amplifier Replace amplifier START