30A Plot Harvester Sampler Attached to John Deere 5400 Forage Harvester

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1 30A Plot Harvester Sampler Attached to John Deere 5400 Forage Harvester Operation Parts Listing Installation Instructions Please retain this document for future reference. RCI Engineering LLC RC080 (12Aug12) 1

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3 1.0 Table of Contents 1.0 Table of Contents Pg Parts Listing....Pg Theory of Operation Pg Purpose and Function of Plot Harvester Sampler....Pg Safety Signs Pg Operation of Unit Pg Engage Harvester..Pg Start Software...Pg Startup..Pg Operator/Field Information. Pg Generate Map.. Pg View Map/Select Start Position.. Pg Begin Harvest of First Plot.. Pg Analysis of Sample.. Pg Recording of Results Pg Error Message.. Pg Stop Operation. Pg Scale Calibration.. Pg Other Functions... Pg NIR Settings..Pg Important Notes.....Pg Maintenance...Pg Contact Information...Pg.43 3

4 2. Parts Listing Note: For service parts, please contact RCI Engineering LLC directly. 2.1 Main Frame Key Part No. Description Qty Notes 1 RC Seat 1 2 RC Frame 1 3 RC Frame 1 Only for PTFH 4 RC Spacer 9 Only for PTFH 5 RC Cell, Load 4 6 RC Cover 1 4

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6 2.2 Diffuser 6

7 Diffuser Parts Key Part No. Description Qty 1 RC Drum 1 2 RC Frame 1 3 RC Support 1 4 RC Diffuser 1 5 RC Bushing 8 6 RC Scraper 1 7 RC Strip 1 8 RC Arm 2 9 RC Support 3 10 RC Cover 1 11 RC Knob 1 12 RC Hinge 2 13 RC Wheel 3 14 RC Collar 1 15 RC Motor 1 7

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9 2.3 Sampler Key Part No. Description Qty 1 RC Assembly, Bearing 1 2 RC Hopper 1 3 RC Sampler 1 4 RC Pan, Scale 1 5 RC Arm 1 6 RC Auger 1 7 RC Bar, UHMW 2 8 RC Slider 1 9 RC Coupler 1 10 RC Motor, Hyd. 1 9

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11 2.4 Belt Frame Key Part No. Description Qty 1 RC Mount, Motor 1 2 RC Motor, Hydraulic 1 3 RC Coupler 1 4 RC0358 Bearing 2 5 RC Roller 1 6 RC Roller, Idler 1 7 RC0411 Bearing Support 2 8 RC0359 Bearing 2 9 RC0416 Bushing 2 10 RC0347 Spring 2 11 RC Belt 1 12 RC Sheet Rubber 1 13 RC Bar 1 14 RC Bar 1 15 RC Scraper 1 16 RC Base 1 17 RC Frame 1 11

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13 3. Theory of Operation 3.1 Purpose and Function of Plot Harvester Sampler This bundle is intended to allow the collection of samples from the forage harvester for data gathering. Figure 1. Function of Plot Harvester Sampling Unit Key 1 - Crop Enters Key 2 Diffuser Key 3 - Belt Key 4 Sub-Sample Auger Key 5 Sample Scale Key 6 Operator Station Key 7 Sample Storage Key 8 PLC / Control Panel Function of Unit Crop from the Forage Harvester enters the diffuser while harvesting. The diffuser drops the material onto the weighing belt. The operator gathers a sub-sample from the auger and places it on the scale for weighing. Once weighed, the sub-sample is stored beneath the seat. The PLC/Control Panel is located to the left of the operator. A display is provided for the operator to note scale weight but is not directly used by the operator in the normal operation of the unit. 13

14 IMPORTANT: 1/ Follow all safety precautions as printed in the John Deere Forage Harvester Operators Manual. 2/ Follow all precautions in this manual. 3/ Take care in transporting this machine over rough terrain and in loading onto trailers for transport due to low ground clearance of the bundle. 14

15 3.2 Safety Signs Safe Operation of Machine Operator Authorization The machine owner must provide the operator of the machine this manual and ensure that the operator reads and understands the contents. This must be performed before the machine is put into operation. Safety Alert Symbol This safety alert symbol is used to alert the operator to the potential for personal injury. Whenever this symbol is noticed in this manual or on the machine, be alert to the situation and read the message near the symbol. Always be alert for the potential for personal injury. General Safety Precautions / Accident Prevention Before operation of the machine each time, check the entire machine for operational safety. 1. The warning and safety decals provide important information to ensure safe operation of the machine. Read and follow these instructions at all times to remain safe. 2. Before operation of the machine, familiarize yourself with all controls of the machine as well as the function of the bundle. 3. Check all guards and shields to make sure they are in place and functional. Replace any defective or missing guards, shields, or components before operation. 4. Avoid loose fitting clothing. The operator should always wear close-fitting clothing and sturdy footwear. 5. Before harvesting begins each time the machine is operated, inspect the area around the machine. Ensure that no one is close to the machine for bystander safety. 6. Keep clear of the working and danger area of the machine. 7. Use caution when working on moveable components of the machine. There are many pinch and shear points. 8. Use proper personal protection for eyes, ears, and head to protect against projected objects and noise. 10. Only start the engine from the operators station with the park brake engaged. 11. Shut off the engine of the machine before performing any service on this unit. 15

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17 Safety Warning Signs Safety Messages Whenever the words and symbols shown below are used in this manual or on the machine, the instructions MUST be followed as they relate to personal safety. DANGER in white letters on a red background indicates an imminently hazardous situation that, if not avoided, will cause death or very serious injury. WARNING in black letters on an orange background indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION in black letters on a yellow background indicates a potentially hazardous situation that, if not avoided, may result in minor injury. Safety Sign Locations 17

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19 4.0 Operation of Unit The following indicates the proper operating procedure for the adaptation bundle. For operation of the Forage Harvester, consult the proper operator's manual. All procedures referenced for either unit are to be performed according to the guidelines of the machine operator manual. 4.1 Engage Harvester Prepare the Forage Harvester for harvesting. See John Deere Forage Harvester Operator's Manual. Once prepared for harvesting, start the computer. IMPORTANT: RSLinx Classic software will automatically start on the PC and needs to run constantly in the background of the PC for the system to operate properly. Do not close this program, but it is permissible to minimize this program. 4.2 Start Software From the desktop of the computer, select the icon for "RCI Plot Harvester" (see Figure 1, Key 1) Figure 1. Desktop for Start of Software Key 1 RCI Plot Harvester Icon 19

20 4.3 Startup The software will now start. Select "Startup" from the "Home" tab. See Key 1, Figure 2. Figure 2. Home Tab Key 1 Start Sampler Button The unit will now start. This will allow the diffuser to operate. IMPORTANT: If the hydraulics are not activated, there is a risk of the machine plugging at the diffuser. In the event of a machine plugging, shut down the forage harvester as outlined in the operator manual. Upon Startup, the system will activate the NIR sensor, perform an internal reference of the NIR sensor, detect the USB status of the NIR sensor, and prepare the unit for operation. When complete, the NIR status indicator will turn Green. 20

21 4.4 Operator / Field Information On the "Home" tab, enter the operator name and field name in the respective fields. Figure 3. Enter Operator Name and Comments Key 1 Operator Name and Comments Boxes 4.5 Generate Map Select the "Generate Map" tab. Enter the information in the fields for "Map Name", "Range", Start Direction", "First Turn", and "Row" fields as indicated in Figure 4 with the values that represent the field about to be harvested. The Increment function of Range/Row is used to skip ranges and/or rows. Simply enter a multiple in this field to skip the increment of ranges/rows. The default value of this field is 1. Select "Generate Map". The map is generated with the information provided, as indicated in Figure 4. The map can also be saved by selecting the Save Map button on the Generate Map Tab. Choose a default location for storing maps. Maps can also be loaded by selecting Load Map button and opening the file for the current plot. Once loaded, select Generate Map to recalculate the map layout. The map can be saved for future reference. Select "Save Map" and save to the map directory, which is a folder in the default C:\Temp directory. A new window will appear for locating the file for saving. 21

22 IMPORTANT: The Field Map name selected when saving the field map will be used as a reference for the data collected. Each data file will have the field map name as part of the file name. Maps previously generated can be reloaded using the "Load Map" function on the "Generate Map" tab. Follow the on-screen instructions for loading the map. Figure 4. Generate Map Function 22

23 4.6 View Map / Select Start Position Select the "Map" tab. The layout of the field is prepared, organized by plot identification for range and row built upon the inputs gathered from the "Generate Map" tab. Verify proper layout of the field. To repair, return to the "Generate Map" tab and adjust the information. Remember to "Generate Map" after each set of changes. On the "Map" tab, select a starting location in the field by selecting the cell with the start location. The arrows in each cell indicate the direction of travel for harvesting. See Figure 5. Figure 5. Selecting Starting Position in Map 23

24 4.7 Begin Harvest of First Plot Return to the "Home" Tab. Place the cursor in the "Plot ID" entity box and press "Enter" on the keyboard. The Plot ID box will highlight to a light green color when the cursor is in the correct position. IMPORTANT: From this point forward, the operator will only need to press enter at the start of harvesting each test plot, the end of each test plot, and the end of every analysis of a test plot. Selecting any other function may cause system error. If an error is made, the unit can be reset by selecting the "Startup" button on the "Home" tab. Once enter is pressed, the message window on the "Home" tab will indicated which plot is to be harvested and which plot is to be harvested next. See Figure 6. Figure 6. Cursor Location for Advancing Plots (First Enter) At this time, the unit is ready for harvesting. Proceed to harvest the first test plot. The sampling unit will collect the sample on the belt scale. Press enter to prepare the unit for harvesting. The status window will indicate that the unit is ready as shown in Figure 6. 24

25 4.8 Analysis of Sample Once the plot is completed, wait for the scales to stabilize and then press enter on the computer again to collect the data. The cursor will remain in the Plot ID box. The operator at the sampling station can indicate when the sample is on the sample scale and alert the machine operator to gather the data. Personal communication devices built into quiet headsets are provided for this reason. An optional method is to press the Gather Data button on the Home tab. This accomplishes the same as pressing enter. See Figure 7. IMPORTANT: The system will not advance if the cursor is not in the Plot ID Box. Figure 7. Analyzing the Plot IMPORTANT: Once the plot data is gathered, the system will clean out and indicate when clean out is complete. The scales will reset to zero approximately two seconds after the clean out is complete. Do not press enter to advance to the next plot until the scales reset to zero. The two second delay is intended to allow the scale systems time to 25

26 average down to the empty value. The operator at the rear of the unit will need to remove the sample while the conveyor is running. This can be communicated through the headset from the operator in the tractor at time of data gathering. To advance to the next plot, press enter once the scales reset to zero. The plot ID will automatically advance. From this point on, the system can be advanced by simply pressing enter to start the plot, and enter to gather the data, or twice per plot. No other input is necessary during normal operation. 26

27 4.9 Recording of Results When the system is finished with the plot, it will automatically save the files to the default directory in a folder with the field name. See Figure 8 for the default location of the files being created. The files are of type *.csv and can be converted with Excel. In addition to the software automatically saving the files, a log file detailing all messages from the message window is saved in the default folders. In addition, a jump drive can be installed on the computer and the files can be stored automatically in the jump drive by entering the drive location as well. However, the tablet PC will not restart with the jump drive installed. It must be removed each time the computer is started from complete shut-down. To change the default location, simply enter the new destination and select Save File Location. IMPORTANT: This function will not interfere with the sequence of pressing enter for movement between functions of harvesting and analysis. It is simply additional information gathered and displayed in the message window. Figure 8. Data File Storage Location 27

28 4.10 Error Messages Error messages regarding unit operation are displayed in the message window on all tabs (bottom of screen) All messages here are also recorded to the log file in the default folder for later reference. In the event of an error, first check to make sure that the system is powered ON and that all cables are connected. The error codes will indicate if there is a communication issue or a failure in the system and are described in the text box. The system will not detect if the hydraulics are not functional, but will indicate if the scale is not cleaned out by showing that the end weight after cleanout did not drop back as predicted. The limits for the scale cleanout warning are on the settings tab as shown in Figure 11. The default value is 2 lbs. When changing the value, simply enter the new value and the system will adopt the value after 1 system cycle. Also, the clean out time (or time that the belt will run during the cleanout cycle) is set on the settings page as shown in Figure 9. The default value is 5 seconds. Always press the Save Settings button when any values on this page are changed. Figure 9. Scale Weight Warning and Clean Out Time 28

29 4.11 Stop Operation A STOP button is incorporated on the Home Tab of the software. This button will stop all outputs of the PLC, but has no control over the forage harvester or hydraulics. To STOP the PLC outputs, simply press the STOP button on the Home tab as shown in Figure 10. WARNING: Always stop all functions and shut off the engine before working on the Plot Sampler, Forage Harvester, or Tractor. Failure to do so may result in serious injury. Figure 10. Stop Button Location 29

30 To reset the software "Stop" Button, select the "Settings" tab and deselect the Stop box as indicated by Figure 11. This overrides the PLC to reset the Stop. Figure 11. Stop Reset 30

31 4.12 Scale Calibration Scales can be recalibrated from the Calibration tab of the software. IMPORTANT: Only recalibrate scales after significant structural work on the scale system. If no significant work is done, the scales should not require recalibration. RCI can also recalibrate your scales or assist remotely with burning the calibration to memory. The calibration procedure requires a fresh battery in the PLC for memory retention if RCI is not burning the values to memory. To recalibrate, first clean both scales and ensure they are empty. Set the computer to the Calibration tab of the software. When scales are stable (and in an area with no wind), enter 0 in the boxes for each scale and press Save for each weight. Then add a known and accurate amount of weight to each scale as follows: Sample scale : Approximately 40 pounds (42 lb John Deere weight) Plot Scale: Approximately 300 pounds (can use 71 pound John Deere weights from tongue if forage harvester is connected to tractor) Enter actual weights in each box on the Calibration Tab. Wait for scale to stabilize and then press enter to accept the weights. The Get Settings button is to recall the last weights used for calibration and is only used for reference. The scale should now be calibrated. See Figure 12. Figure 12. Calibration Tab 31

32 4.13 Other Functions On the Home tab, there are several buttons that may be used as needed. The Zero Scales button is used to reset the scales in the event that material may have been removed after the scales had been automatically set to zero. The Manual Cleanout button is used to cycle the cleanout function in the event that the operator desires to do so. This also will zero the scales after cleanout. The NIR Reference button is used by the operator to manually reference the NIR sensor. This is recommended to be performed every few hours throughout the day or more often during greater temperature changes. The software will automatically reference the NIR unit during startup so it is important that the NIR be powered on at least 30 minutes before starting the software. The Manual NIR Read button is used to manually trigger the NIR sensor for a sample. It is also tied to the F8 key. A sensor is installed on a switch in the spout to automatically start the NIR at the appropriate time. This button is provided in the event of a failure of the switch so that the user can manually start the NIR while harvesting a plot if needed. The Home screen is equipped with an indicator for the Switch to show when it is open or closed. This is for indication only. The Gather Data button is provided for users that wish to touch the screen to collect data. This performs the same function as if the enter button was pressed with the cursor in the Harvest Plot ID box. The constituent results are displayed to the right side of the screen. These are controlled in the Settings2 Tab. See the NIR Settings Section for more information. IMPORTANT: Do not cycle either function while the system is in the automatic cleanout mode or before the scales are automatically reset to zero. This may cause an error in the software logic. If this does occur, move the cursor from the Plot ID box to the Comments box and then back to the Plot ID box. Information regarding operation and sequence / data gathered is displayed in the lower window on the Home Tab. This window can be scrolled to look back over previous data. This information is all gathered in the log file in the default folder. See Figure

33 Figure 13. Home Tab and Associated Functions 33

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35 5.0 NIR Settings The RCI Plot Harvester Software controls the John Deere NIR sensor. The results of which are displayed on the Home tab of the software. The settings controlling the NIR sensor are found on the Settings and Settings2 tabs of the software. On the Settings tab, the Constituents are listed on the right side of the screen. This layout will match the layout of the Home tab. The Constituents are listed in the right columns. These fields must match the calibration files of the NIR page exactly in order to function. The Calibration file names can be found in the column headers of the NIR sensor Measure Page ( ). The moisture value on the Home tab is calculated from the DM value used. There is no calibration directly for moisture. Use the Save Settings button to save settings to memory in the software. The NIR Usage selection indicates where the NIR sensor is located. The software will restart when this is changed in order to display the correct fields. Do not change this setting once the machine is configured properly. See Figure 14. Figure 14. Settings Tab 35

36 Additional settings for the NIR are located on the Settings 2 tab. Synchronize Time With NIR is provided for manual synchronization of time between the computer and the NIR sensor. This is done automatically at startup of the software. It is critical to synchronize the time between the two to make sure that data collection is referenced properly. The NIR Analysis Delay is provided as a time delay for the NIR to start after the switch is closed. The Interval Reference is the timer for the Internal Reference of the NIR. The default value here is 600 minutes (10 Hours) as the operator will manually reference the NIR unit during operation so as to not interfere with sampling operations. The Measure Time is used to determine the duration of the NIR analysis. The default value is 8 seconds, and 5 to 8 seconds is recommended for each plot. The Valid Spectra Frame Count is provided for the internal workings of the NIR sensor. The default value is 100 and should not be changed. Each of the settings has a Set button which is used to program the setting to the NIR. The Save Settings button is used to save all settings in the software to internal memory of the software so as to repopulate the fields upon restart. The NIR USB Status indicates if the USB drive is detected. If connected, do not use the Disconnect button as the drive would then need to be physically removed from the system and reinstalled. The software will automatically detect the drive on startup. The Repacks is used for in-lab analysis and should be set to 1 when used in the field. This provides for one sampling to average into one result. The NIR Turntable Status is provided to switch to Automatic Mode for in-lab sampling. When on the machine, this should be set to Manual. The user can turn the turntable on or off when in a lab configuration. See Figure

37 Figure 15. Settings 2 Tab 37

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39 6.0 Important Notes The following are important notes on the sampler. 1) There are two scale units in the PLC control box. These are for analysis of the load cells only and should not require any physical work by the user. The screen readings may not match the measurement in the software. The scale units are used to provide the in-motion weigh logic to smooth out the signal for accurate results. The system is calibrated in the software and the system may not display exactly the same as the display at the operator station. Do not attempt to recalibrate the system. This is done by factory personnel only. 2) Do not cycle either function while the system is in the automatic cleanout mode or before the scales are automatically reset to zero. This may cause an error in the software logic. If this does occur, move the cursor from the Plot ID box to the Comments box and then back to the Plot ID box. 3) Always refer to the Operator Manuals of the Forage Harvester for any service and safety functions of the machines. 4) In the event of an error in the operation of software and controls, always check connections and power supply first. Then try to power down the system and restart both the plot harvester and computer to reset the communication to resolve. 5) See the NIR Manual provided with the John Deere NIR sensor for any other NIR settings or operations not covered by this manual. Keep in mind that settings must be returned to default by this manual for the software to work properly with the NIR sensor. 6) Data Exporting All data collected is stored in the C:\temp directory. This directory can be copied and taken on a USB Drive to remove from the PC. Also, the software can copy the data directly to a USB Drive attached to the computer with the settings tab used for configuration. It is important to remove the USB Drive from the NIR Sensor Control Box once per year and clean it off. This removal process is covered in the NIR Operator Manual. 39

40 7.0 Maintenance The following are important notes for maintenance of the sampler. Greasing There are no greaseable bearings on the sampler unit. Hydraulic System The Hydraulic Reservoir at the Front Right Wheel should be filled to the bottom of the suction screen with Universal TransHydraulic Fluid. The Hydraulic Fluid should be changed at the end of the season to remove any moisture that may accumulate in the tank. The Hydraulic Filter can be sourced at a local NAPA Store. Conveyor Belt The belt should be removed annually for cleaning. Belt Tension Adjustment The belt tension for all belts is maintained by a set of springs on the idler roller of the belt frame assembly. These springs are used to apply a specific amount of load on the belt for proper tensioning. First, always inspect the rollers to make sure they are clean of debris. Clean as necessary. Note: : The three M12 Lock nuts that retain the bearing carrier to the belt frame must be tightened such that the washer under the lock not cannot freely turn and the bolt head is completely engaged in the slot (approximately 10 lbf-ft (14 N-m)). Over-tightening will not allow the bearing carrier to slide in the slots of the belt frame, which will lead to improper adjustment of belt tension. Do not tighten the bolts further after the belt tension adjustment is made as the bearing carrier must be able to slide along the frame as the belt stretches over time. Note: Failure to maintain proper belt tension may result in poor belt performance, belt slippage, and overall shortened belt service life. 40

41 Follow the steps below to adjust belt tension. Begin at the rear of the belt frame. First, loosen the jam nut (Key 3) on the adjustment bolt (Key 2). Tighten the adjustment nut (Key 1) to compress the spring and move the idler roller (Key 4) outward to tension the belt. Continue to tighten the adjustment nut (Key 1) until the stop bushing (Key 5) can no longer freely turn by hand. Tighten the jam nut (Key 3). Figure 16. Roller Adjustment Key 1 Adjustment Nut Key 2 Adjustment Bolt Key 3 Jam Nut Key 4 Idler Roller Key 5 Stop Bushing Repeat process on the other side of the belt frame as well. 41

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43 8.0 Contact Information For further support of this sampler unit, please contact: RCI Engineering LLC 970 Metalcraft Drive Mayville, WI Attn: Product Support Phone: Fax:

44 44

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