DirectCommand Installation Case/Flexi-Coil/New Holland Air Cart Kit (Variable Rate Electro Hydraulic Systems) Ag Leader Technology

Transcription

1 Part Name/Description Part Number Quantity Flexi-Coil Air Seeder Kit Generic Cable Installation Kit Hardware Kit Large Module Deutsch Dust Plug 8-pin Quick Reference Guide Installation Instructions CAN Y-Splice CAN Terminator Plug DC Motor Driver Module Granular Strip-Till Module CAN Bus Stub 14 in Ag Leader Fan Speed Cable 15 ft Cable 12V PWM Motor Power 6ft Tractor High Current Power Cable 22 ft High Power Implement Cable 28 ft Case/Flexi-Coil Channel Cable 14 ft Case/Flexi-Coil Channel Cable 17 ft Dielectric Grease.14oz Mounting Plate Large Module/DC Motor Driver Mounting Hanger Flexi-Coil Air Cart Encoder Reeve Coupler Mounting Strap Encoder Anti-Rotation Hardware Kit Drill Bit Pilot 1/4in Cord Grip PG Removal Tool Weatherpack Installation Kit Bin Level Sensor Compression Spring 3.75in., SS Anti-Seize Compound 7 Gram Pouch Hex Nylock -3/8in., SS Mounting Bracket Implement Plug Hole Saw 15/16in PN: Rev. D January 2014 Page 1 of 29

2 DirectCommand Installation This kit supports the following systems utilizing Ag Leader Granular Strip- Till and DC Motor Driver Modules: -Case ADX-2180,2230,*3380,*3430 -Case Precision Air- 2230,2280,2330 -Flexi-Coil- 2340, 2850, 3350, *3850, *4350 -New Holland- P1030, P1040, *P1050, *P1060 *Indicates a three bin machine. Additional components for third channel of control must be ordered separately. Note: This kit does not support interfacing factory Meter Shaft Rate Sensors, Low Bin Sensors, Ultra-Sonic Bin Level Sensors, Air Velocity Sensors, or Fan Speed Sensor. Note: This kit only supports a single fan speed sensor configuration. This DirectCommand Kit also requires the installation of a Display Kit or Display Cable Kit, Auxiliary Input Module with 10-Boom Switch Box or CAN Switch Box Kit and Air Seeder Sensors for correct operation. Air Seeder Sensors (Purchase Separately) Part Number Quantity Meter Shaft Encoder Thru-Bore Bin Level Sensor Fan Speed Sensor Important Notices You will save time and prevent wrong installation of components by closely following these step-by-step instructions. If you have questions, call at Ext 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 Page 2 of 29 January 2014 PN: Rev. D

3 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. Section Contents Section Heading Page Common Components 4 System Layout 5 Safety Notices 6 Installing the Granular Strip-Till Control Module and DC Motor Driver Modules 7 Installing the CAN Bus Harness and Power Harness 9 Installing the Air Seeder Sensors 11 Installing the Control Cables 24 Installing the Implement Switch (optional) 26 Setting Up the Display 28 PN: Rev. D January 2014 Page 3 of 29

4 DirectCommand Installation Common Components This section contains illustrations of components common to all Direct Command Installations. Their purpose is to ensure proper identification and installations in the sections that follow. CAN Bus Connectors 1. Terminator PN: Plug (Not all applications) PN: Y-Splice PN: Granular Strip-Till Module PN: DC Motor Driver Module PN: DC Motor Driver Module PN: Page 4 of 29 January 2014 PN: Rev. D

5 Component and Cable Layout PN: Rev. D January 2014 Page 5 of 29

6 DirectCommand Installation Safety Notices CAUTION: Hydraulic equipment should be on safety stops, hydraulic pressure relieved with machines systems turned off and all machine motion stopped before starting work. 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 holes, wiring or controls that could be damaged when drilling any holes. IMPORTANT: Disconnect the Display, DirectCommand components and any speed sensors 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 a Null Modem Cable, included in the Display Kit, to prevent damage to the Display or GPS receiver. IMPORTANT: Use Dielectric grease to coat the seals and terminals of each connector that will be exposed to weather or chemicals as you plug them in. IMPORTANT: Use Anti-Seize Lubricant to coat the threads of encoder mounting hardware and inside surfaces of encoder inserts that will be exposed to weather or chemicals. 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 29 January 2014 PN: Rev. D

7 Installing the Granular Strip-Till Control Module and DC Motor Driver Modules Parts required for procedure: From DirectCommand Kit (1) Hardware Kit Large Module PN: (1) Hardware Kit 8 PN: (1) Granular Strip-Till Control Module PN: (2) DC Motor Driver Module PN: (1) Mount Large Module/Motor Driver PN: (2) Mount Hanger Flexi-Coil Air Cart PN: Step-by-Step instructions for installing the Granular Strip- Till Control Module DC Motor Driver Modules 1. The Granular Strip-Till Control Module and DC Motor Driver Modules should be mounted at the location referenced in the figure below in order for all the control cables to reach machine components. Module Mounting Location On Right Rail Above Frame Note: This mounting location will allow easy access to the control modules without interference from the loading auger, and help to limit exposure from the elements. PN: Rev. D January 2014 Page 7 of 29

8 DirectCommand Installation 2. Locate the Mounting Plate-Large Module/DC Motor Driver, PN: and the 2 Mounting Hangers, PN: in the DirectCommand kit. Using hardware provided, secure Mounting Hangers to Mounting Plate Module Mounting Plate and Mounting Hangers 3. Locate the Granular Strip-Till Control Module PN: and two DC Motor Driver Modules, PN: Using Hardware provided, secure modules to Module Mounting Plate. Control Module Assembly Note: If mounting a third DC Motor Driver Module, it will be necessary to install longer mounting hardware to accommodate the third module. Page 8 of 29 January 2014 PN: Rev. D

9 4. Install control module assembly at recommended mounting location below in order for all cables to reach machine components. 5. Measure, mark, and drill hole to allow mounting of module mounting plate assembly. Drill access hole here. Existing Hole Module Mounting Plate Assembly Installing the CAN Bus and Power Harness Parts required for procedure: From DirectCommand Kit (1) Generic Cable Installation Kit PN: (1) CAN Bus Stub 14 in. PN: (1) High Power Implement Cable 28ft. PN: (1) High Power Tractor Cable 22ft. PN: (1) CAN Y-Splice PN: (1) CAN Terminator Plug PN: (1) Mounting Bracket Implement Plug PN: Optional Items Purchased Separately Cable Kit Air Seeder Imp. Ext. 33ft. PN: Cable Kit Air Seeder Imp. Ext. 46ft. PN: Step-by-Step instructions for installing the CAN Bus and Power Harness 1. Connect the ring terminals on the High Power Tractor Cable 22ft., PN: to the battery, or power studs in the cab. Connect the ring terminal with fuses to the positive terminal, and connect the ring terminal with black wires to the battery ground. PN: Rev. D January 2014 Page 9 of 29

10 DirectCommand Installation 2. Route the opposite end of the High Power Tractor Cable into the cab towards the Display Cable. 3. Plug the 3-pin Weatherpack tower on the High Power Tractor Cable into the mating shroud on the Display Cable. 4. Connect the 4-pin CAN plug on the High Power Tractor Cable into the open receptacle on the CAN Y-Splice. 5. Route the round 6-pin Deutsch receptacle on the opposite end of the High Power Tractor Cable out of the cab. 6. Included in the DirectCommand Kit is a Mounting Bracket, PN: This bracket can be connected to the 6-pin Deutsch receptacle on the Tractor Power Cable and then fastened to the tractor to secure the connection point. Mounting hardware provided in the Kit. 7. Locate the High Power Implement Cable 28ft., PN: in the DirectCommand Kit. 8. Connect the single end of the CAN Y-Splice from DirectCommand Kit into the mating 4-pin ITT Cannon plug on the Implement Cable. 9. Connect the CAN Terminator Plug, PN: to the black side of the CAN Y-Splice from the previous step. 10. Connect the 4-pin gray Deutsch plug on the 14 in CAN Bus Stub, PN: into the receptacle labeled CAN Bus on the Granular Strip- Till Module. 11. Connect the opposite end of the CAN Bus Stub into the gray side of the CAN Y-Splice installed on the High Power Implement Cable. 12. Connect one of the 2-pin gray power plugs on the High Power Implement Cable into the 2-pin receptacle coming out of the Granular Strip-Till Module. 13. Connect the remaining 2-pin gray power plugs on the High Power Implement Cable into the 2-pin receptacles on the DC Motor Driver Modules. 14. Route the opposite end of the High Power Implement Cable towards the front of the Seeder to be connected to the High Current Tractor Cable. Page 10 of 29 January 2014 PN: Rev. D

11 15. If necessary, extension cable kits may be purchased for additional length. Refer to the table below for available lengths. Optional Cable Extension Kits Length Part Number 33 ft ft Installing the Air Seeder Sensors Parts required for procedure: (2) Bin Level Sensor PN: (2) Installation Kit Bin Level Sensor PN: (1) Fan Speed Sensor PN: (1) Hardware Kit 8 PN: (1) Drill Bit 1/4in. PN: (2) Meter Shaft Encoder Thru-Bore PN: (2) Encoder Reeve Couplers PN: (2) Mounting Strap Anti-Rotation PN: (2) Cord Grip PG 16 PN: (1) Weatherpack Removal Tool PN: (1) Anti-Seize Compound Silver PN: (4) Compression Springs 3.75 PN: (1) Hole Saw 15/16in. PN: Step-by-Step instructions for installing the Air Seeder Sensors Fan Speed Sensor Installation 1. Locate factory fan speed sensor on the backside of the fan assembly. PN: Rev. D January 2014 Page 11 of 29

12 DirectCommand Installation Fan Assembly Ag Leader Fan Speed Sensor Mounting Location Factory Fan Speed Sensor Fan Speed Sensor Mounting Location Note: Do not remove the factory sensor from the fan assembly. Make sure factory sensor cabling is secured away from moving parts. 2. Install the gear tooth fan speed sensor and bracket on the bearing flange bolt using existing nut to secure bracket to the flange. Refer to Fan Speed Sensor Installation Guide, PN: included with the Fan Speed Sensor Assembly. Note: Alteration of the Fan Speed Sensor Bracket will be required to ensure proper fit. Page 12 of 29 January 2014 PN: Rev. D

13 Fan Speed Sensor and Bracket Installed 3. Secure sensor cabling away from moving parts using cable ties. Bin Level Sensor Installation 1. Locate the bin level sensor installation kit, PN: Place one plastic nut approximately 1.5 in. from the face of the Bin Level Sensor, PN: Bin Level Sensor Assembly With Installation Bracket PN: Rev. D January 2014 Page 13 of 29

14 DirectCommand Installation 3. Feed the front of the bin level sensor through the hole in the bracket. 4. Place the second black plastic nut onto the front side of the sensor to secure the bracket. 5. Use the 3/8in. X 3-1/2in. Hex Cap Screws, 3/8in. Nylock Nuts, Bin Level Sensor bracket, and stainless steel plate to fasten the bin level sensor to the ladder rail inside bin. Suggested Bin Level Sensor Mounting Location 6. Move the bracket with sensor up or down the ladder rail to set your desired low bin level position. 7. Using the 1/4 in. drill bit, PN: and 15/16in. Hole Saw PN: included in the kit, carefully drill access hole at the recommended location from outside the tank to allow access to bin level sensor mounted inside the tank in the previous step. Page 14 of 29 January 2014 PN: Rev. D

15 8. Mount the Cord Grip, PN: , in the 15/16in. hole drilled through the bin wall in the previous step. Cord Grip 9. Use the Weatherpack removal tool, PN: , to extract the sockets from the 4 socket Weatherpack tower on the Case/Flexi-Coil Channel Cable, PN: PN: Rev. D January 2014 Page 15 of 29

16 DirectCommand Installation Weatherpack Removal Tool Weatherpack Socket Removal Note: Be careful not to damage the Weatherpack sockets or seals while removing the wires from the tower. Disassembled Cable 10. Carefully feed the disassembled cable through the Cord Grip from outside the tank. Page 16 of 29 January 2014 PN: Rev. D

17 11. From inside the tank, slide the plastic nut from the Cord Grip assembly over the disassembled cable ends. Slide nut down cable and secure to threads of Cord Grip assembly installed through tank wall in Step 8. Disassembled Cable w/cord Grip Nut 12. Reassemble the 4 socket Weatherpack tower and wires on the inside of the bin. Note the following wire locations: A=red (power) B=black (ground) C=white (signal) D=WP plug 13. Tighten the Cord Grip onto the cable to seal the bin. 14. For each additional bin, repeat steps PN: Rev. D January 2014 Page 17 of 29

18 DirectCommand Installation Meter Shaft Encoder Installation 1. Locate the Metering Shaft Encoder, PN: purchased separately. 2. Attached the anti-rotation bracket to the encoder at the 11 o clock position using the hardware provided with the encoder. Anti-Rotation Bracket Installed 3. Locate the Encoder Coupler, PN: in the Direct Command Kit. With encoder mounting collar loosened, slide coupler through the encoder opening. Encoder Mounting Collar Metering Shaft Encoder and Coupler Page 18 of 29 January 2014 PN: Rev. D

19 Encoder Coupler Installed Note: Do not tighten the encoder mounting collar. This will be done as a last step in installation of the meter shaft encoder. Metering Shaft Assembly Mounting Location PN: Rev. D January 2014 Page 19 of 29

20 DirectCommand Installation 4. Remove factory nut and bolt from coupler that couples the hydraulic torque generator to the meter shaft. Hydraulic Torque Generator Remove Bolt Meter Shaft Factory Torque Generator And Meter Shaft Coupling Assembly 5. Remove factory motor bracket mounting hardware one at a time and replace with hardware provided in kit. Remove Removal of Factory Motor Bracket Hardware 6. With longer motor bracket mounting hardware installed, slide motor Page 20 of 29 January 2014 PN: Rev. D

21 assembly backwards and remove factory coupler from meter shaft. Uncoupling Torque Generator from Meter Shaft 7. Slide Ag Leader encoder assembly onto the torque generator shaft and reinstall factory nut and bolt removed in step 5. Ag Leader Meter Shaft Encoder Installed Note: It is highly recommended that anti-seize provide in kit be applied to hardware surfaces to protect against corrosion. PN: Rev. D January 2014 Page 21 of 29

22 DirectCommand Installation Anti-Rotation Assembly 8. Locate the 3/8in. x 5-1/2in. Hex Cap Screw, PN: , 3/8in. Hex Serrated Flange Nuts and 3/8in. Flat Washers in the DirectCommand Kit. Insert 3/8in. X 5-1/2in. Hex Cap Screw with 3/8in. Washer through hole in the direction indicated below and secure with one 3/8 in. Serrated Flange Nut. 9. Locate the 2 in. Mounting Strap Anti-Rotation Adapter, PN: in the kit. Secure anti-rotation adapter using two 3/8in. serrated flange nuts aligning strap with the anti-rotation bracket installed on the meter shaft encoder leaving the nuts hand tight. Mounting Strap Anti-Rotation Adapter Page 22 of 29 January 2014 PN: Rev. D

23 10. Locate the two 3/8in. black plastic insulating washers in the Rate Encoder Box and 3/8in. x 1in. Carriage Bolt and 3/8in. Hex Serrated Flange Nut provide in the kit. Insert the Carriage Bolt through the Black Anti-Rotation Strap. Slide one of the black insulating washers onto the end of the Carriage Bolt. 11. Insert the end of the carriage bolt through the opening in the Encoder Anti-Rotation Bracket. Slide the remaining insulating washer onto the Carriage Bolt. Thread the 3/8in. Serrated Flange Nut onto the Carriage Bolt leaving the nut hand tight. Completed Anti-Rotation Assembly 12. Once the desired alignment is achieved, tighten all hardware on the anti-rotation assembly. 13. Tighten the encoder mounting collar with a 7/64 hex key. 14. For additional metering shafts repeat steps PN: Rev. D January 2014 Page 23 of 29

24 DirectCommand Installation Installing the Control Cables Parts required for procedure: From DirectCommand Kit (1) Generic Cable Installation Kit PN: (1) 8-pin Deutsch Dust Plug PN: (1) Cable Flexi-Coil Air Cart Channel (14ft) PN: (1) Cable Flexi-Coil Air Cart Channel (17ft) PN: (1) Cable Ag Leader Fan Speed (15ft) PN: (2) Cable 12V PWM Motor Power (6ft) PN: Step-by-Step instructions for installing the Control Cables 1. Connect the gray 8-pin Deutsch plug from the Case/Flexi-Coil Air Cart Channel Cable (14FT), PN: to the receptacle marked CHANNEL 1 on the Granular Strip-Till Module. 2. Route the opposite ends of the Channel Cable, around the back of the module mounting plate, along the right side of the machine, and on the back side of the frame to the Channel 1 Bin Level Sensor, Meter Shaft Encoder and input of DC Motor Driver Module. 3. Connect the gray 3-pin Deutsch plug from the Channel Cable to the mating 3-pin Deutsch receptacle on the Meter Shaft Encoder. 4. Connect the 4-pin Weatherpack tower from the Channel Cable to the mating 4-pin Weatherpack shroud on the Bin level sensor. 5. Connect the black 2-pin Deutsch plug from the Channel Cable to the mating 2-pin black receptacle on the Channel 1 DC Motor Driver Module. 6. Route remaining cable with 2-pin Weatherpack tower labeled Meter Switch across to factory Meter Switches located on the left side of machine. 7. Disconnect the 2-pin Weatherpack connector from Channel 1 Meter Switch. 8. Connect 2-pin Weatherpack tower of Meter Switch Cable to mating receptacle of the Channel 1 Meter Switch 9. Locate the 12V PWM Motor Power Cable PN: in the Direct Command Kit. Page 24 of 29 January 2014 PN: Rev. D

25 10. Connect the gray 2-pin Deutsch receptacle from the 12V PWM Motor Power Cable to the mating 2-pin Deutsch plug on the DC Motor Driver Module. 11. Route the opposite end of the 12V PWM Motor Cable back along the right side of the machine to the Channel 1 Electric Motor Drive. 12. Disconnect the 2-pin Weatherpack connector from the Electric Motor Drive. 13. Connect the 2-pin Weatherpack tower of the 12V PWM Motor Power Cable to the mating receptacle of the Electric Motor Drive. 14. For additional control channels repeat steps 1-13 with the appropriate channel cable. 15. If unused, install the 8-pin Deutsch Dust plug, PN: into the Channel 3 receptacle on the Granular Strip-Till Module. 16. Locate the Fan Speed Cable (15ft), PN: in the DirectCommand Kit. 17. Connect the black 12-pin Deutsch plug from the Fan Speed Cable to the receptacle labeled AUXILIARY on the Granular Strip-Till Module. 18. Remove the 3-pin Weatherpack shroud implement jumper from the mating 3-pin Weatherpack tower on the Fan Speed Cable. 19. Connect the 3-pin Weatherpack tower in the previous step to the mating 3-pin Weatherpack shroud on the High Power Implement Cable, PN: If no implement switch is used connect the 3-pin Weatherpack shroud implement jumper, removed in step 11, to the 3-pin Weatherpack tower on the opposite end of the High Power Implement Cable. 21. Route the 3-pin Weatherpack tower, on the Fan Speed Cable, toward the Fan Speed Sensor. 22. Connect the 3-pin Weatherpack tower from the Fan Speed Cable to the Mating 3-pin Weatherpack Shroud on the Fan Speed Sensor. 23. Use cable ties to secure all cables away from pinch points, sharp edges and moving parts. PN: Rev. D January 2014 Page 25 of 29

26 DirectCommand Installation 24. If cable previously installed on machine will not be removed, coat terminals of open connectors with dielectric grease to help prevent corrosion. Installing the Implement Switch (Optional) Parts required for procedure: Optional Items Purchased Separately Implement Switch PN: Implement Switch Ext. Cable (10 ft) PN: Implement Switch Ext. Cable (25 ft) PN: Step-by-Step instructions for installing the Implement Switch 1. Remove the 3-pin Weatherpack shroud with a jumper wire from the High Power Implement Cable, PN: and save for future use. NOTE: If an implement switch is not connected, the jumper wire must be installed on the High Power Implement Cable for Granular Strip-Till Module to apply product. 2. Decide on a location for mounting the implement switch. 3. The mounting orientation of the Implement Switch Assembly determines whether the lever is off center or centered when the implement is in the application position. Implement Switch Installation Orientation 4. For an off center orientation plug the 3-pin Weatherpack Shroud labeled NORMALLY OPEN on the Implement Switch into the 3-pin Weatherpack Tower on the opposite end of the High Power Implement Cable. Page 26 of 29 January 2014 PN: Rev. D

27 5. For a centered orientation plug the 3-pin Weatherpack Shroud labeled NORMALLY CLOSED on the Implement Switch into the 3-pin Weatherpack Tower on the opposite end of the High Power Imp. Cable. Note: If necessary, an Implement Switch Extension Cable may be installed to provide additional length between the High Power Implement Cable and Implement Switch. Note: When using an implement switch with the High Power Extension Cable be sure to connect the Weatherpack Shroud on the extension cable to the mating Weatherpack tower on the Implement cable. PN: Rev. D January 2014 Page 27 of 29

28 DirectCommand Installation Setting Up the Display 1. Refer to the Strip-Till section of the display manual for setting up the AgLeader Display. Initial setup will vary depending on configuration and sensors used. 2. For general controller setting information refer to refer to the Quick Reference Guide, PN: Enter the initial values from the following tables for initial setup Setting Name Control Valve Configuration PWM Frequency Controller Settings Channel Tab Default Value PWM 100 Gain* 500 Zero RPM Offset Allowable Error 10 2% Description Setting specifies the type of control valve being used for the rate control functions of the controlling system. The frequency that the PWM control valve is pulsed at. Settings can be found from the manufacturer of the valve. Typical settings range from Hz. Determines how aggressively the control valve responds when making spinner speed adjustments. The higher the value the more aggressive the system response is. NOTE: Leaving all other valve control settings at the default value and making a small adjustment to the Gain is usually all that is required to finetune the control system. Represents the maximum duty cycle that is sent to the control valve without producing any hydraulic flow from the PWM valve. Using too high of a Zero RPM Offset value can cause the spinner system to not properly shut off. See the PWM valve manufacturer information for recommended settings. Determines the percent of error that is allowed prior to the product control system making any flow rate changes. 2% - 3% is the normal dead band setting range. Too low of a setting value can cause the product control system to continually hunt for the target application rate. Too high of a setting will cause excessive product application error. Page 28 of 29 January 2014 PN: Rev. D

29 Shaft Speed Cal Max Metering Speed The number of pulses that are generated by the sensor during one revolution of the meter shaft. Setting determines the maximum RPM of the conveyor that controls product distribution to the application point. Fan Speed Cal Controller Settings Auxiliary Tab 3 The number of pulses that are generated by the sensor during one revolution of the hydraulic fan. Min Speed Max Speed Low Fan Speed Check Box Rate Not Responding Threshold Default is 0 Default is 6000rpm Default is unchecked 30% User definable value which determines the minimum allowable fan speed for application. User definable value which determines the maximum allowable fan speed for application. Checking the Low Fan Speed Shutoff check box shuts off hydraulic fan when fan RPM falls below user defined minimum fan speed value. Percent difference between actual rate applied and target application rate. 4. Verify correct Speed Cal numbers are used for the Auger Speed and Fan Speed Sensors. Note: The shaft speed calibration number for the AgLeader encoder is 600 pulses/revolution. Note: If it becomes necessary to change one of these settings, make changes to one value at a time so you can evaluate the changes accurately. PN: Rev. D January 2014 Page 29 of 29