ULTRA Linear Operators Manual

Irrigation CompanyHastings, Nebraska

ULTRA Linear System

OPERATION AND TROUBLESHOOTING MANUAL

CD90461 January 2011 PLC Vers. 0.4.16 to 0.4.20

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1/25/2011 ULTRA Linear Operators Manual 1

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1. INTRODUCTION......................................................................................................................................... 51.1. General Information ........................................................................................................................................... 5

1.1.1. Qualified Operators .................................................................................................................................. 51.1.2. Maintenance ............................................................................................................................................. 5

1.2. Guidelines for System Operation ....................................................................................................................... 5

1.3. ULTRA Linear Components .............................................................................................................................. 6

1.4. ULTRA Linear System Operation Modes Overview........................................................................................... 61.4.1. Linear Mode.............................................................................................................................................. 61.4.2. Pivot Mode................................................................................................................................................ 71.4.3. 0 Zero Position vs. 180 Position of Spans ........................................................................................... 71.4.4. Rotation of Tractor for L-Shaped Field ..................................................................................................... 71.4.5. Towable Option ........................................................................................................................................ 8

1.5. Linear System Guidance Notes (See Section 5.1) ............................................................................................ 81.5.1. System Guidance - keeps spans perpendicular to the Tractor ................................................................. 81.5.2. Tractor Guidance - keeps Tractor on straight path ................................................................................... 91.5.3. Storage of Rotation Arm and Tie Rod ..................................................................................................... 10

2. CONTROL PANEL ................................................................................................................................... 112.1. Control Panel Overview ................................................................................................................................... 11

2.2. Board Power Up and Keypad Operation ......................................................................................................... 12

2.3. Setting Speed & Direction of the System ......................................................................................................... 12

2.4. STATUS Key ................................................................................................................................................... 13

2.5. DATE/TIMES Key ............................................................................................................................................ 13

2.6. SYSTEM SETUP Key ...................................................................................................................................... 13

2.7. EG AREAS Key ............................................................................................................................................... 15

2.8. AUX APPL Key ................................................................................................................................................ 15

2.9. GUID SETUP Key ........................................................................................................................................... 16

2.10. RUN SETUP Key ............................................................................................................................................. 17

2.11. TEST/ENTER Key ........................................................................................................................................... 19

2.12. SAFETY HISTORY Key .................................................................................................................................. 19

2.13. Direction Override Pushbuttons ....................................................................................................................... 19

2.14. Distance Counter ............................................................................................................................................. 202.14.1. Distance Counter Explanation ................................................................................................................ 202.14.2. Distance Counter Use Set to Auto Stop or Auto Reverse .................................................................... 202.14.3. Distance Counter Use AUX APPL ....................................................................................................... 21

2.15. Example Programming .................................................................................................................................... 21

3. INITIAL START-UP OF SYSTEM ............................................................................................................ 233.1. Setup of Control Panel .................................................................................................................................... 23

3.2. Initial Start-up Checklist ................................................................................................................................... 25

3.3. Operational Check of Safeties Wired into PLC Panel ...................................................................................... 27

3.4. Operational Check of Safeties Generated by PLC Panel ................................................................................ 27

4. OPERATION OF SYSTEM ....................................................................................................................... 284.1. Linear Mode General Operation ................................................................................................................... 28

4.1.1. Make sure stop locations are set. ........................................................................................................... 284.1.2. Set the 0 or 180 Span Position. ......................................................................................................... 284.1.3. Set Zero Position of BEI Encoder. .......................................................................................................... 29

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4.1.4. Set the Direction and Application of the System. .................................................................................... 294.1.5. Use SYSTEM Toggle Switch to control movement of system. ............................................................... 294.1.6. Automatic Speed Control of System. ...................................................................................................... 294.1.7. All Toggle Switches up (RUN) before leaving the field. .......................................................................... 294.1.8. Auto Stop or Auto Reverse of System. ................................................................................................... 30

4.2. Linear Mode Hose Drag ................................................................................................................................ 304.2.1. Water Shutoff Valve Operation. .............................................................................................................. 304.2.2. Couple Hose to Tractor, Plug Other Side. .............................................................................................. 314.2.3. Hose Change Operation. ........................................................................................................................ 31

4.3. Linear Mode Ditch Feed ............................................................................................................................... 324.3.1. Linear Water Pump Priming and Operation, 12VDC Vacuum Primer. .................................................... 324.3.2. Linear Water Pump Priming and Operation, Hydraulic Motorized Primer. .............................................. 32

4.4. Pivot Mode Pivoting the Spans ..................................................................................................................... 344.4.1. Make sure physical stop location is set in addition to programmed stop location. .................................. 344.4.2. Connect Anchor Chains to Tractor. ......................................................................................................... 344.4.3. Set system to PIVOT MODE in RUN SETUP. ........................................................................................ 344.4.4. Set Direction and Speed on STATUS Screen 1. .................................................................................... 354.4.5. Use SYSTEM Toggle Switch to control movement of system. ............................................................... 354.4.6. Appropriate Toggle Switches up (RUN) before leaving the field. ............................................................ 35

4.5. Rotation of Tractor for L Shaped Field .......................................................................................................... 354.5.1. Rotate Tractor Must be in LINEAR Mode. ........................................................................................... 364.5.2. ENABLE Rotate Ultra Tractor 90 Degrees. .......................................................................................... 364.5.3. Set Tractor Wheels into ROTATE position. ............................................................................................ 364.5.4. Disengage 2 Gears (Diagonal from each other). .................................................................................... 364.5.5. Switch Tractor (Right Side) Direction Coils on Hydraulic Panel. ............................................................. 374.5.6. Set Guidance out of the way to Rotate if Above Cable or Furrow or Ditch Guidance. ............................ 374.5.7. Tell Panel System is Ready to Rotate. ................................................................................................... 374.5.8. Exit RUN SETUP and access STATUS Screen 1................................................................................... 374.5.9. Set Rotation Direction on STATUS Screen 1. ........................................................................................ 384.5.10. Start Tractor Rotating, Then Set Speed. Stop Rotation when Finished. ................................................ 384.5.11. Set Tractor Equipment Back to Linear Operation ................................................................................... 384.5.12. Pivot Spans Perpendicular to Tractor. .................................................................................................... 38

4.6. Towable Option ............................................................................................................................................... 394.6.1. Set Linear Spans into Tow Position. ....................................................................................................... 394.6.2. Set Tractor Guidance. ............................................................................................................................. 394.6.3. Disconnect Water Supply Connections. .................................................................................................. 394.6.4. Prepare Pull Side of Tractor to Tow. .................................................................................................... 394.6.5. Prepare Trailing Side of Tractor to Tow. ............................................................................................... 404.6.6. Disengage ALL Gears. ........................................................................................................................... 404.6.7. Adjust Tie Clevis so System Tracks Straight. ......................................................................................... 404.6.8. Begin Towing System ............................................................................................................................. 40

4.7. Using ETSEN PRI & REF SFTY ...................................................................................................................... 414.7.1. Disable in RUN SETUP ........................................................................................................................ 414.7.2. SYSTEM Toggle to RUN Position, Operate System ............................................................................... 41

5. GUIDANCE OF ULTRA LINEAR .............................................................................................................. 425.1. Linear System Guidance ................................................................................................................................. 42

5.1.1. Uses Angle Sensor in Collector Ring ...................................................................................................... 425.1.2. Zero BEI Encoder Angle in GUID SETUP .............................................................................................. 425.1.3. Keep Connections Tight ......................................................................................................................... 425.1.4. Alignment Cables Tight, System in Alignment 5.1.4a Check Lower Swivel Elbow ................................ 425.1.5. Use TEST SCREEN 3 to Monitor System Guidance. ............................................................................. 435.1.6. Excessive Angle will Push or Pull Tractor. .............................................................................................. 43

5.2. Tractor Guidance Overview .......................................................................................................................... 445.2.1. Hydraulic Circuit...................................................................................................................................... 445.2.2. Hydraulic Control Panel Circuit ............................................................................................................... 445.2.3. Oil Flow Path .......................................................................................................................................... 455.2.4. Steering .................................................................................................................................................. 45

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5.3. Tractor Guidance Above Ground Cable ....................................................................................................... 465.3.1. Components ........................................................................................................................................... 465.3.2. Proximity Controller Operation ................................................................................................................ 465.3.3. SAFETY & SYSTEM Toggle Switches ................................................................................................... 465.3.4. Linear Logic Board in Tractor Guidance Panel ....................................................................................... 475.3.5. Use of Components ................................................................................................................................ 47

5.4. Tractor Guidance Buried Wire ...................................................................................................................... 485.4.1. Buried Wire Guidance Components ....................................................................................................... 485.4.2. Buried Wire Guidance Tractor Panel ...................................................................................................... 485.4.3. Use of Components ................................................................................................................................ 48

6. TROUBLESHOOTING ............................................................................................................................. 496.1. Safety Messages Switches Wired to PLC Engine May Die when 117 Released. ......................................... 49

6.2. Safety Messages Caused by PLC Quick Reference .................................................................................... 50

6.3. Other Problems Quick Reference ................................................................................................................. 50

6.4. PLC Control Panel Circuit Board ..................................................................................................................... 51

6.5. Right End Tower Control Manifold Components ............................................................................................. 52

6.6. Point Manifold PCB (Printed Circuit Board) ..................................................................................................... 52

6.7. Tractor Hydraulic Panel Components (Left End) ............................................................................................. 53

6.8. Tractor Control Panels Electric & Hydraulic .................................................................................................. 55

6.9. Above Cable Tractor Guidance Troubleshooting ............................................................................................. 706.9.1. General Overview ................................................................................................................................... 70

6.10. Buried Wire Tractor Guidance Troubleshooting .............................................................................................. 716.10.1. General Overview ................................................................................................................................... 716.10.2. Guidance Board Indicator LEDs. ........................................................................................................... 726.10.3. Low or No Oscillator Signal. ................................................................................................................... 726.10.4. Guidance Board PRI LED on. .............................................................................................................. 73

6.11. Tractor Pushed or Pulled off Guidance ............................................................................................................ 736.11.1. Excessive Angle will Push or Pull Tractor. .............................................................................................. 73

6.12. BEI Encoder Not Reading. .............................................................................................................................. 736.12.1. Check Wiring of BEI Encoder. ................................................................................................................ 736.12.2. Check Jumpers on PLC Bd and RX1 LED. ............................................................................................ 746.12.3. Check Power and Signal Lines. .............................................................................................................. 74

7. APPENDIX 1: CALIBRATION OF ROLLING RADIUS .......................................................................... 75

8. APPENDIX 2: WIRING DIAGRAMS ....................................................................................................... 778.1. Cable Routing (Jan. 2008 April 2010) .......................................................................................................... 77

8.2. Cable Routing (May 2010 - )................................................................................................................... 78

8.3. Precision Linear Control Panel Internal Wiring Top Half vers 4 & 5 Bd ........................................................ 79

8.4. Precision Linear Control Panel Internal Wiring Bottom Half vers. 4 & 5 Bd. ................................................. 80

8.5. Power & Safety Conns. Wiring ........................................................................................................................ 81

8.6. Tractor Hydraulic Manifold Panel Wiring (May 2010 - ) ............................................................................ 82

8.7. Above Ground Guidance Tractor Panel Wiring (Jan. 2008 April 2010) ....................................................... 83

8.8. Above Ground Guidance Tractor Panel Wiring (May 2010 - ) ............................................................... 84

8.9. PLC Panel to Above Ground Tractor Guidance Panel Wiring ......................................................................... 85

8.10. Buried Wire Guidance Tractor Panel Wiring (Jan. 2008 April 2010) ............................................................. 86

8.11. Buried Wire Guidance Tractor Panel Wiring (May 2010 - ) ..................................................................... 87

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8.12. PLC Panel to Buried Wire Tractor Guidance Panel Wiring .............................................................................. 88

8.13. Straddle Ditch Guidance Tractor Panel Wiring (Jan. 2008 April 2010) ........................................................ 89

8.14. Straddle Ditch Guidance Tractor Panel Wiring (May 2010 - ) ............................................................... 90

8.15. PLC Panel to Straddle Ditch Tractor Guidance Panel Wiring .......................................................................... 91

8.16. PLC Panel 20/15 Swivel Cable Wiring ............................................................................................................. 92

8.17. Water Pressure Sensor Wiring ........................................................................................................................ 92

8.18. Collector Ring Wiring ....................................................................................................................................... 93

8.19. Right End Tower Wiring ................................................................................................................................... 94

9. APPENDIX 3: Service Parts ................................................................................................................... 95

10. APPENDIX 4: Set-Up Records ............................................................................................................... 96

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1. INTRODUCTION

1.1. General Information This ULTRA Linear Operators Manual is to be used in conjunction with the standard T-L PIVOT OPERATORS MANUAL and LINEAR HOSE DRAG or DITCH FEED OPERATORS MANUALS. Please read these manuals completely before operation of the system. If any questions arise, please contact your T-L Dealer.

1.1.1. Qualified Operators Personnel operating the ULTRA Linear System must be experienced with operating mechanized irrigation systems and must have read this entire Operators Manual. Knowledge of system operation is essential for safe and reliable performance.

1.1.2. Maintenance For the pivot spans and drive train, follow the recommended Service and Maintenance procedures as described in the T-L PIVOT OPERATORS MANUAL. Additional maintenance items for the ULTRA Linear Tractor are described later in this manual.

1.2. Guidelines for System Operation The following guidelines have been established from experience with T-L linear systems. These guidelines must be followed for satisfactory linear performance. 1. A STRAIGHT Guidance Cable or Buried Wire is the most important single item for successful operation.

The guidance reference (above ground cable or buried wire) should be surveyed straight from end to end. Above Ground Cable: The cable should run 1/2 way up from the bottom of the guidance wand. The cable must be kept free of weeds and obstructions. Install end of cable stops at the end of each run.

2. A Flat, Uniform, Dry, Hard Roadway for the tractor is necessary for proper guidance and traction. The

roadway must be maintained free of wheel tracks or ruts and must be solid to minimize wheel slippage. The roadway must be maintained to minimize the dirt pulled in the hose loop.

3. Wheel tracks must be controlled on all towers. A dry pass followed by a light application on the first

irrigation is required to establish a track base and reduce the possibility of deep rutting on subsequent irrigations. Wheel track depth should not exceed 4-6" and should be filled if they cause guidance shut downs. Special caution should be taken with pivoting linears to reduce wheel tracks.

4. Deep Furrows parallel to the tracks of the system MUST be avoided, as they can put a side load on the

system and cause guidance and structural problems. Row Crops can be planted parallel to the tower tracks BUT the rows MUST be planted perfectly parallel to the wheel tracks. Planting perpendicular to wheel tracks may be done on shallow furrows.

5. The Maximum Side Slope is 3% measured perpendicular to the direction of the travel. 6. The Maximum Slope of 5% should not be exceeded along the travel path of the system. 7. Sudden or Extreme Terrain Changes should be avoided because they can cause excessive

compression or tension and/or guidance irregularity. 8. Minimum Travel Speed on all T-L Linears is 8 Inches per Minute. 9. Install the Physical Barricades for the Right end tower at the field ends.

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1.3. ULTRA Linear Components

Figure 1. ULTRA Linear System Components

1.4. ULTRA Linear System Operation Modes Overview 1.4.1. Linear Mode

- Left End (Tractor) and Right End move the same direction and same speed (unless steering).

Figure 2. Linear Mode Operation. Figure 3. Ultra Tractor in Linear Mode.

Forward - facing controls. - to the Left.

Reverse - facing controls. - to the Right.

Precision Linear Control Panel (PLC)

Tractor Guidance Control Panel

Tractor Hydraulic Control Panel

May 2010 change to Yellow Panel (Manifold Assy).

Collector Ring with Encoder

ULTRA TRACTOR RIGHT END TOWER

Auto Stop/ Reverse Assy

End Tower Manifold

Engine Panel

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1.4.2. Pivot Mode - Left End (Tractor) stationary, Right End determines pivoting speed and direction.

Figure 4. Pivot Mode Operation. Figure 5. Spans in Pivot Mode.

1.4.3. 0 Zero Position vs. 180 Position of Spans - When the spans are pivoted 180 degrees, they will be over the control panels.

Figure 6. Span Position 0 or 180.

1.4.4. Rotation of Tractor for L-Shaped Field - Spans pivoted 90 degrees. Tractor can be Rotated 90 degrees. See later section for details.

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Figure 7. Rotation of Tractor.

1.4.5. Towable Option - System can be towed from either side of the ULTRA tractor. See later section for details.

Figure 8. Towing System.

1.5. Linear System Guidance Notes (See Section 5.1) 1.5.1. System Guidance - keeps spans perpendicular to the Tractor

- Uses Encoder in Collector Ring to measure the angle between spans and tractor.

Figure 9. Encoder in Collector Ring. Figure 10. Measure Angle. - Keep fit-up tight for improved sensitivity.

Figure 11. Fit-up Snug for Improved Sensitivity.

Encoder in Collector Ring Measures Angle.

Keep Shims in place and tight.

Nipple tied to fork.

- Set Screw Tight.- Fork snug. - Mounts tight.

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- Make sure Jumpers are in place on the back of the PLC Board and that RX1 is flashing. Figure 11a. Check PLC Board.

1.5.2. Tractor Guidance - keeps Tractor on straight path - Uses Above Ground Cable, Buried Wire, Furrow, or Concrete Ditch for reference line. - Guidance components on tractor should be set so the tractor follows the same path in Forward

and Reverse. - Explained in more detail later.

Figure 12. Buried Wire Guidance Figure 13. Above Cable Guidance

- Steers Tractor by changing speeds of tires on each side.

Figure 14. Tractor Guidance Operation.

Jumpers on J6 and J8.

RX1 LED flashing

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- Make sure Guidance Components are set properly (Above Ground Cable or Buried Wire).

Figure 15. Guidance Component Checks.

1.5.3. Storage of Rotation Arm and Tie Rod Figure 16. Storage Location for Rotation Arms and Tie Rods.

ROTATIONARM

TIE ROD(TOW OPTION)

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2. CONTROL PANEL

2.1. Control Panel Overview

Figure 17. Control Panel Overview. 1 Backlit LCD Screen: Backlighting turns off after 2 minutes of no key presses. Press any

key to turn backlighting on. 2 Keypad: 12 Keys for operator use. See explanations following for more detail. 3 Power Switch: RUN = Operation with Engine Running. PROGRAM = Setup with Engine Off, powered direct from battery. (Note: System can run in Program, but battery will

drain after system shutoff Panel will stay powered.) 4 System Switch: RUN = Start End Towers moving the set spd & dir., Log Safeties. STOP = Stop End Towers from moving. (Note: Toggle from STOP to RUN to STOP to save

changes made to application rate on Status Screen.) 5 Safety Switch: RUN = Safeties from Tractor Guidance Panel active. (Note: Leave in RUN Position, unless system has tracked off of

guidance cable or wire. Under normal operation, must be in RUN before SYSTEM switch (4) is moved to RUN.

START = Ignore Safeties from Tractor Guidance Panel. 6 Water Pressure Switch: RUN = Analog Water Pressure and Switch Gauge active. START = Ignore Water Pressure safeties, run system dry. 7 Hydraulic Pressure Sw.: RUN = Hydr. Tank 1500 PSI Switch active. START = Ignore Hydr. Tank 1500 PSI Switch. (Note: MUST BE IN RUN position before leaving field.)

1

FWD APPL 0.75 AS STEERING = L1:R2

3

4

2

6

7

5

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2.2. Board Power Up and Keypad Operation

Figure 18. Board Power-Up & Keypad Operation.

2.3. Setting Speed & Direction of the System Use the DIRECTION Key to select FWD or REV, Use the + and - keys to adjust the Application Rate. Test Screen 1 will show the travel speed.

Figure 19. Setting System Speed and Direction.


T-L IRRIGATION

PRECISION LINEAR CONTROL V4.11

AUTO STOP SAFETY THR 11/30/06 10:58A

(Press Enter)

Title Screen

Safety Message (after safety shutdown)

Status Screen 1 (default screen)

Press Key to access function. Press Key again to exit.

DIRECTION Key - Toggles FWD & REV

+ & - Keys - Adjust Appl. in 0.05

increments.

SET IPM 018 LEFT SENSOR * RIGHT SENSOR *

Test Screen 1 shows speed.

FIRMWARE VERSION MUST BE 0.4.11 or later. (03.1 or earlier will NOT

work with ULTRA.)

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2.4. STATUS Key Press STATUS key to advance through screens.

Line 1 = Direction, Application Line 2 = Auto Stop or Auto Rev STATUS SCREEN 1 Line 3 = End Guns On (if used) Line 4 = Steering Status (AO shown if in Anti-Oversteer) Line 1 = Current Date & Time STATUS SCREEN 2 Line 2 = Dist. to AS or AR Line 3 = Current Position Line 4 = Time to Set Dist STATUS SCREEN 3 Line 2 = Analog Water Pressure (if installed.) Line 4 = Water Flow (if installed.)

2.5. DATE/TIMES Key Press DATE/TIME Key to access this function, press again to return to STATUS screen. Press + - to change values, Press TEST/ENTER to advance, DIRECTION key to back up.

Displays current Day of Week Displays Date (mm:dd:yy) Displays current Time (As set on Screen 3) CURR TIME = Time since SYSTEM Toggle placed

in RUN for current operation. USER TIME = Accumulated time in RUN position.

User can reset to 0 in RUN SETUP. TOTAL TIME = Accumulated time in RUN position.

Reset to 0 only when reprogrammed. Set mm:dd:yy Set Day of Week Set Time of Day Set AM or PM

2.6. SYSTEM SETUP Key Press SYSTEM SETUP Key to access this function, press again to return to STATUS screen. Press + - to change values, Press TEST/ENTER to advance, DIRECTION key to back up.

English or Metric Distance to End + EG Throw

WED 7/29/08 10:23A SET DIST=02600 ft CURR DIST=02475 ft

013:42:16 TO STOP

WATER PRESSURE 38 PSI WATER FLOW 1145 GPM

FWD APPL 0.75 AS EG L R STEERING = L1:R1 AO

SET DATE 12/25/04 SUN SET TIME 12:01 SET AM/PM P

TUE 01/24/06 12:52:43 P

RUN TIMES HR:M:S CURR 00013:29:41 USER 00106:07:13 TOTAL 01890:52:58

UNITS English IRRIGATED WIDTH 01300 Ft

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Hose Drag or Ditch Feed Water Flow to Linear (GPM or l/sec) Gear Ratio of Left End (Tractor) Rolling Radius of Left Tire 14.9 X 24 = 23.5 / 59.7cm 16.9 X 24 = 24.0 / 61.0cm 11.2 X 38 = 27.0 / 68.6cm Gear Ratio of Right End Rolling Radius of Right Tire NOTE: Adjust Rolling Radius of Right & Left. See Calibration of Rolling Radius. Enter Max Speed of System 60 IPM (152 cm/min) unless noted otherwise - MIN APPL will be calculated. Adjustment rate of MFC Speed Control sec/IPM - Set vs. Actual Speed Comparison - Set to 0.018 (.008 if metric) - If speed overshoots, enter lower number. Yes or No Full Scale PSI rating of Sensor If Analog Water Pressure: - Safety set point pressure and time Initial Time = time it takes to build water pressure at startup. Yes or No Gal. per Pulse from flowmeter Ultra or Single Tower Tractor - Ultra Tractor has 2 sets of towers and a

swivel pivot point.

LEFT (TRACTOR) GEAR 68:1 LEFT (TRACTOR) TIRE 23.5 In Roll Radius

WATER SUPPLY Hose Drag WATER FLOW 0800 GPM

MAX SPD 060 IPM MIN APPL 0.15 in

SPD ADJ RATE LEFT 0.018 sec/IPM SPD ADJ RATE RIGHT 0.018 sec/IPM

ANALOG WATER PRESS Yes IF YES, FULL SCALE 100 PSI

WATER FLOW METER Yes IF YES 1.25 GAL/PULSE

LOW WATER PRESS 12 PSI 0:30 m:s INITIAL TIME 15:00

RIGHT GEAR 68:1 RIGHT TIRE 23.5 In Roll Radius

LINEAR TYPE Ultra

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2.7. EG AREAS Key Press EG AREAS Key to access this function, press again to return to STATUS screen. Press + - to change values, Press TEST/ENTER to advance, DIRECTION key to back up. NOTE: Consider End Gun Areas with Spans in 180 Position will they be used? DISABLE?

Disable = End Guns will not activate. Note: Range set by Distance in LINEAR Mode Range set by Degrees in PIVOT Mode Range 1 for Right EG (if used) Range 2 for Right EG (if used) Range 1 for Left EG (if used) Range 2 for Left EG (if used) IF set to PIVOT MODE in Run Setup, allow 2 Right EG Areas by degrees:

2.8. AUX APPL Key Press AUX APPL Key to access this function, press again to return to STATUS screen. Press + - to change values, Press TEST/ENTER to advance, DIRECTION key to back up.

Enable or Disable If Disable, following screens not shown 1st Application rate change in FWD (if used) Range for 1st Appl change in FWD (Set low to high, ex. 500 to 1000) 2nd Application rate change in FWD (if used) Range for 2nd Appl change in FWD (Set low to high, ex. 1500 to 2000) 1st Application rate change in REV (if used) Range for 1st Appl change in REV (Set high to low, ex. 2000 to 1500) 2nd Application rate change in REV (if used) Range for 2nd Appl change in REV (Set high to low, ex. 1000 to 500)

RT END GUN AREA 1 ----- ft To ----- ft RT END GUN AREA 2 ----- ft TO ----- ft

LF END GUN AREA 1 ----- ft To ----- ft LF END GUN AREA 2 ----- ft TO ----- ft

AUX APPL ENABLE

FWD AUX1 APPL 0.00 000 IPM FWD AUX1 APPL RANGE 00000 ft To 00000 ft

FWD AUX2 APPL 0.00 000 IPM FWD AUX2 APPL RANGE 00000 ft To 00000 ft

REV AUX1 APPL 0.00 000 IPM REV AUX1 APPL RANGE 00000 ft To 00000 ft


EG AREAS ENABLE

RT END GUN AREA 1 XXX.X To XXX.X deg RT END GUN AREA 2 XXX.X To XXX.X deg

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2.9. GUID SETUP Key Press GUID SETUP Key to access this function, press again to return to STATUS screen. Press + - to change values, Press TEST/ENTER to advance, DIRECTION key to back up.

NOTE: This is the System Guidance Setup - keeps the spans perpendicular to the Tractor. IMPORTANT NOTE: Settings shown are factory defaults and are recommended for proper

system performance. Consult your T-L Dealer before changing settings. (Except for setting the 0 degree location of the BEI Encoder.)

If ULTRA Tractor selected in System Setup - BEI Encoder is the only choice. If Single Tower Tractor Selected, choices are: - Above Cable SRH280 or Buried Wire Time Steering Signal must be present before changing steering ratios. Time to remain steering once steering has been changed. YES or NO Encoder must be set to 0 when spans are perpendicular to the tractor. (For Linear Mode operation.)

Figure 20. Set Encoder Angle to 0 Degrees.

Angle at which to change to 2:1 - one end 2X faster than other Angle at which to change to 3:1 - one end 3X faster than other Angle at which Primary Safety occurs. (10 second delay) Degrees angle must increase before anti-oversteer initiation. Degrees angle must decrease before steering returns to 1:1.

GUIDANCE TYPE BEI Serial Encoder

STEERING SIG TIME 004 secs. STAY STEERING TIME 012 secs

ANTI OVRSTR OUT 1.0 Deg ANTI OVRSTR IN 1.0 Deg

2:1 STEERING ANGLE 0.5 Deg 3:1 STEERING ANGLE 1.0 Deg

SET BEI ENCODER TO 0 NO IF YES Press Enter at 0 deg

PRIMARY SAFETY LEVEL 6.0 Deg

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Degrees wand must increase again after 1:1 anti-oversteer, to return to steering condition (2:1 or 3:1 depending on setting)

2.10. RUN SETUP Key Press RUN SETUP Key to access this function, press again to return to STATUS screen. Press + - to change values, Press TEST/ENTER to advance, DIRECTION key to back up.

Set Distance to Auto Stop (or Auto Reverse if Ditch Feed) NOTE: This is the SET DIST on Status Screen 2, per Direction. Set time to remain at AS/AR location before shut down (AS)or reversing (AR) IF Ditch Feed Selected in SYSTEM SETUP, the following screen will show up: FWD, REV, BOTH, or NEITHER Direction to Auto Reverse if Ditch Feed (Default is AS, unless told to AR) Continue here: Yes or No If Yes, change the CURR DIST shown on Status Screen 2 to the value entered here. The following 2 screens displayed ONLY if Distance not set properly CURR DIST cannot be reset to distance greater than FWD SET DIST CURR DIST cannot be reset to distance less than REV SET DIST Continue here: Yes or No Resets the USER TIME displayed on DATE/TIMES Screen 2 to 0000:00:00.

ANTI OVRSTR BACK OUT 1.0 Deg

AR/AS SET POINTS FWD = 10000 ft. REV = 00000 ft. AR/AS DELAY 00 Min

RE-SET DISTANCE NO. IF YES 00000 ft.

RESET USER RUN TIME TO ZERO NO

NOT ALLOWED: DISTANCE GREATER THAN FWD AR/AS SET-POINT

DITCH FEED AUTO REVERSE DIR. FWD

NOT ALLOWED: DISTANCE LESS THAN REV AR/AS SET-POINT

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Enable or Disable Allows disabling of Safeties so operator can temporarily run (10 minute timeout) - See following section If ETSEN PRI & REF SFTY set to Disabled, the following screen shows: (Explained in more detail in later section.) MFC valves set (End Tower Flow Control Valves) to known position. Manual speed adjustment allowed, see following section.

Continue Here Linear or Pivot

If LINEAR Mode selected, then set the SPAN POSITION to either 0 Zero or 180.

Mode must be set to LINEAR if tractor is to be Rotated.

If OPERATING MODE set to PIVOT, the following screens will be displayed: Linear or Pivot

If PIVOT Mode selected, then set the DIST TO THE END TOWER.

If going to Pivot the ULTRA Spans, then enter the

CURRENT ANGLE of the Spans and the destination ANGLE TO PIVOT TO.

Status Screen 1 will reflect Pivot Mode. Allow use of Overwater Timer in PIVOT MODE - If End Tower gets stuck, degrees wont change If Enabled, enter the Max Time to move 1 Degree - Range = 1 to 90 Minutes. - If the Angle has not changed 1 Degree (Up or

Down) in the set time, cause a safety. Continue Here Default = Right

On End Feed, Ditch units, the Left End (Tractor) could be used for the Distance Counter.

If Left End was selected, but then set to PIVOT mode, end to use will change to RIGHT.

Enable or Disabled (v 0.1.W on) If Enabled, occurs if 12VDC Power falls below 10.8 VDC. SYSTEM toggle in RUN. Default is DISABLE. If ENABLE, see ROTATION of TRACTOR section. Operating Mode must be LINEAR to Rotate

Tractor.

ETSEN PRI & REF SFTY ENABLE

OPERATING MODE LINEAR SPAN POSITION 0 Zero

MFC VALVES ADJUSTING WAIT 45 SECONDS

OPERATING MODE PIVOT DIST TO END TOWER 1000 ft

CURRENT ANGLE 000 deg ANGLE TO PIVOT TO 180 deg

END TO USE FOR DISTANCE COUNTER Right

OVERWATER TIMER ENABLE TIME TO MOVE 1 DEG. XX min

ROTATE ULTRA TRACTOR 90 DEGREES DISABLE

LOW POWER SAFETY ENABLE

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2.11. TEST/ENTER Key Press TEST/ENTER Key to access this function, press again to return to STATUS screen.

Press + or - to scroll through screens. Set Travel Speed for selected Appl. Rate Asterisk flashing indicates respective Speed Sensor is operational. Displays Set Speed for each end - based on Steering Ratio Displays Actual End Tower Speed for each end + or - displayed when speed is being changed. - speed changes occur every 10 seconds for 6

times, then every 30 seconds. If OPERATING MODE set to LINEAR, the following screens will be displayed:

Angle of Spans to Tractor Asterisk flashing shows comm. with encoder. Spans in 0 Position. Shows if spans are Ahead or Behind or in Center. Displays Set Speed, and Set Steering Speeds AO displayed if in Anti-Oversteer, L& R speeds

equal.

2.12. SAFETY HISTORY Key Press SAFETY HISTORY Key to access this function, press again to return to STATUS screen.

Press + or - to scroll through screens. Displays last 8 safeties, 2 per screen.

2.13. Direction Override Pushbuttons IMPORTANT: For momentary operation only, do not use for extended periods. Pushbuttons are located on the PLC Circuit Bd, upper left. - Open Inside Door Panel for access.

Figure 21. Direction Override Pushbuttons


LEFT SET IPM 012 LEFT ACT IPM 014 - RGHT SET IPM 024 RGHT ACT IPM 022 +

FWD ANGLE 00.5 deg * 0 00.0 SPANS BEHIND SET018 L018 R018 AO

S1 PRIMARY SAFETY 04/30/08 11:22A S2 AUTO STOP SAFETY 04/18/08 8:48P

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2.14. Distance Counter 2.14.1. Distance Counter Explanation

- Position of the system in the field is determined by the distance the system travels. - Uses Sensor Motor, Gear Ratio and Tire Rolling Radius to determine travel distance. - User selects end to use, either Right or Left, to determine distance traveled. - Hose Drag = Right end more practical, no wheel slip. - Hose Drag can only be Auto Stopped at set distance, cannot be auto reversed. - Ditch Feed = Left end (Tractor) can be used. - Ditch Feed can Auto Stop or Auto Reverse at set distance - For accuracy, perform Rolling Radius Calibration Appendix 1.

Figure 22. Distance Counter.

2.14.2. Distance Counter Use Set to Auto Stop or Auto Reverse Step 1. RUN SETUP = Set Auto Reverse Step 2. RUN SETUP = IF Ditch Feed, or Auto Stop locations, delay time. set direction(s) to Auto Reverse. Step 3. RUN SETUP = Reset Current Step 4. STATUS Screen 1 = Set Direction Distance (current location). & Appl. Rate. Start moving. Step 5. STATUS Screen 2 = View Set & Curr Distance. (If Dir. set to FWD) (If Dir. set to REV)

AR/AS SET POINTS FWD = 2600 ft. REV = 00000 ft. AR/AS DELAY 05 Min

RE-SET DISTANCE YES. IF YES 00500 ft.

WED 7/29/08 10:23A SET DIST=02600 ft CURR DIST=00500 ft 013:42:16 TO STOP

DITCH FEED AUTO REVERSE DIR. FWD



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2.14.3. Distance Counter Use AUX APPL - AUX APPL is used to change the speed of the linear for a specified range in the field. - Two different AUX APPL ranges can be set in the FWD Direction and two in REV. - NOTE: When programming in REV, start at the upper range. - System will travel at APPL speed programmed on STATUS screen 1 for other ranges.

REV AUX APPL example:

2.15. Example Programming - ULTRA Hose Drag Example Use Position Stop for hose change location. - System will Auto Stop when CURR DIST = SET DIST or when ET Switch activated. - For a Ditch Feed Linear, Auto Reverse can be selected.

Figure 23. Example Programming

Explanation of Operation for this Example:

FORWARD

From To Dir Mode Applic Rt EG

0 ft 600 ft FWD Fwd Spd 1.00 in Off

600 ft 1300 ft FWD Fwd Aux1 0.75 in Off

At 1300 ft = Tractor Gd Primary or Position Stop Safety for Hose change. (instant shutdown.)

1300 ft 1700 ft FWD Fwd Aux1 0.75 in Off

1700 ft 2000 ft FWD Fwd Aux1 0.75 in ON

2000 ft 2600 ft FWD Fwd Aux2 0.50 in ON

At 2600 ft = Reverse Switch on Right End Tower activated. Change direction (REV) 23 Seconds, then stop & Delay 5 Minutes. Then shut down with Auto Stop Safety.



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REVERSE

From To Dir Mode Applic Rt EG

2600 ft 2000 ft REV Rev Spd 1.00 in ON

2000 ft 1700 ft REV Rev Aux1 0.75 in ON

1700 ft 1300 ft REV Rev Aux1 0.75 in Off

At 1300 ft = Tractor Gd Primary or Position Stop Safety for Hose change. (instant shutdown.)



At 0 ft = Reverse Switch on Right End Tower activated. Change direction (FWD) 23 Seconds, then stop & Delay 5 Minutes. Then shut down with Auto Stop Safety.

Following are the settings for this Example: SYSTEM SETUP Item Setting Choices/Units Water Supply Hose Drag Hose Drag or Ditch Feed RUN SETUP Item Setting Choices/Units AR/AS Setpoint FWD 2650 ft (programmed beyond so AR/AS Switch stops it) AR/AS Setpoing REV 0 ft AR/AS Delay Timer 5 min. Re-Set Distance Yes (System is at home location) Enter Distance 10 ft (So AR/AS switch stops it in REV, & not 0 ft) Re-Set User Run Time to Zero ______ Yes/No (User Preference) ETSEN Pri & Ref Sfty Enable Operating Mode Linear Span Position 0 Zero End to Use for Distance Counter Right (Left End on Hose Drag = slippage, not accurate) Rotation of Tractor Disable AUX APPL Enable

Fwd Aux1 Appl 0.75 in. XXX IPM 600 ft To 2000 ft

Fwd Aux2 Appl 0.50 in. XXX IPM 2000 ft To 2650 ft

Rev Aux1 Appl 0.75 in. XXX IPM 2000 ft To 600 ft

Rev Aux2 Appl 0.50 in. XXX IPM 600 ft To 000 ft

EG AREAS

Enable

RT EG Area 1 1700 ft To 2600 ft

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3. INITIAL START-UP OF SYSTEM 3.1. Setup of Control Panel

- Place POWER Toggle Switch in PROGRAM position to allow for programming with engine off. - Enter the Setup information for each item. Refer to previous section for help. - Record information here for future reference.

DATE/TIMES Item Setting Choices/Units Screen 1 N/A Display current date & time, Hr:Min:Sec Screen 2 N/A Display the Run Times Screen 3 ______ Enter date (mm/dd/yy), day, time and AM or PM SYSTEM SETUP (defaults) Item Example Setting Choices/Units Units English ______ English or Metric Irrigated Width 1285 ______ Ft Water Supply Hose ______ Hose Drag or Ditch Feed Water Flow 800 ______ GPM Left (Tractor) Gear 68:1 ______ Left (Tractor) Tire 23.5 ______ Right Gear 68:1 ______ Right Tire 23.5 ______ Max Speed 60 ______ IPM Min Appl. .20 ______ in. Spd Adj Rate Left .018 ______ sec/IPM Spd Adj Rate Right .018 ______ sec /IPM Analog Water Pressure Yes ______ Yes/No Full Scale 100 ______ 0 to 200 (Max Pressure on 4 to 20 mA sensor) Low Water Press 12 ______ psi 00:30 ______ mm:ss Initial Delay 15:00 ______ mm:ss Water Flow Meter Yes ______ Yes/No Gal/Pulse 1.25 ______ Linear Type ULTRA ______ EG AREAS EG AREAS Enable/Disable

Linear Mode Settings Item Setting Item Setting

LF EG Area 1 ________ ft To ________ ft RT EG Area 1 ________ ft To ________ ft

LF EG Area 2 ________ ft To ________ ft RT EG Area 2 ________ ft To ________ ft

Pivot Mode Settings Item Setting

RT EG Area 1 _______deg To _______deg

RT EG Area 2 _______deg To _______deg



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AUX APPL AUX APPL Enable/Disable

Item Appl Speed Distances

Fwd Aux1 Appl _____ in. _____ IPM _________ ft To _________ ft

Fwd Aux2 Appl _____ in. _____ IPM _________ ft To _________ ft

Rev Aux1 Appl _____ in. _____ IPM _________ ft To _________ ft

Rev Aux2 Appl _____ in. _____ IPM _________ ft To _________ ft

GUID SETUP (defaults) Item Example Setting Choices/Units Guidance Type BEI Encoder BEI Above Cable SRH280 or Buried Wire Steering Sig Time 4 ______ sec Stay Steering Time 12 ______ sec Set BEI Angle to 0 ______ Yes/No (Set to 0 degrees at startup) Press Enter at 0 2:1 Steering Angle 0.5 ______ deg 3:1 Steering Angle 1.0 ______ deg Primary Safety Level 6.0 ______ deg Anti Ovrstr Out 1.0 ______ deg Anti Ovrstr In 1.0 ______ deg Anti Ovrstr Back Out 1.0 ______ deg RUN SETUP Item Setting Choices/Units AR/AS Setpoint FWD ______ ft AR/AS Setpoing REV ______ ft AR/AS Delay Timer ______ min. Ditch Feed Auto Reverse (if Ditch) ______ FWD, REV, Both, NEITHER Re-Set Distance ______ Yes/No, Enter Distance ______ ft Re-Set User Run Time to Zero ______ Yes/No ETSEN Pri & Ref Sfty ______ Enable/Disable Operating Mode ______ Linear/Pivot Span Position (Linear Mode) ______ 0 or 180 End to use for Distance Counter ______ Left or Right Low Power Safety ______ Enable/Disable Rotate Tractor 90 Degrees ______ Yes/No



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3.2. Initial Start-up Checklist ____ 1. Set-Up of Control Panel Complete. - verify firmware version is 0.4.11 or later, and circuit board has 256 processor. - Set to ULTRA in System Setup - Set to LINEAR Mode in Run Setup, with 0 or 180 Span Position selected. - FWD Setpoint and REV Setpoint Distances set in Run Setup - Current Distance Reset in Run Setup to allow system to operate both FWD & REV. - Disable AUX APPL for initial start-up and testing. ____ 2. All Oil Lines flushed properly to eliminate contamination. ____ 3. Verify that the BEI Encoder in the Collector Ring is communicating with the PLC Panel. - With Power switch in PLC Control Panel set to PROGRAM, go to Test Screen 3. - Check that the asterisk in the upper right corner flashes about once every 2 seconds. Asterisk flashes every 2 seconds. - If asterisk is not flashing, see Troubleshooting section. ____ 4. Set BEI Encoder to zero in GUID SETUP of PLC Panel.

- NOTE: Spans may not be perpendicular to tractor yet, but they should be close. - Fine tuning of zero location will occur once system is operational.

____ 5. All wiring complete. ____ 6. Coils on Right End Tower Manifold switched so TOP = Fwd, BOTTOM = Rev. ____ 7. Diesel engine operational. - Set Manual Bypass Valve on Hydraulic Tank to Open position. - With Power switch in PLC Control Panel set to RUN, start and run engine. ____ 8. Hydraulic system plumbing complete, check for NO LEAKS. - With Power switch in PLC Control Panel set to RUN, start and run engine. - Set Manual Bypass Valve on Hydraulic Tank to Closed position: - Intermediate towers should walk into line. - Hydraulic Pressure should stabilize at 1750 psi ____ 9. Align all towers. - See Pivot Operators Manual. - Keep Alignment Cables adjusted tight. This is a MUST for proper linear operation. ____ 10. Test PLC Speed and Direction Control. - All Toggle Switches on PLC Panel set to down position. (Start or Stop position) - Then Power switch in PLC Control Panel set to RUN, start and run engine. - Set Manual Bypass Valve on Hydraulic Tank to Closed position. - On Status Screen 1, set Direction to FWD and Appl to 0.50. - Move System switch in PLC Panel to RUN position. - End Towers should start to move within 10 to 20 seconds. - NOTE: MFC (Motorized Flow Control) valves are shipped in closed position. System must

run for 20 to 30 seconds to allow these valves to open.

FWD ANGLE 00.0 deg * 0 00.0 CENTER SET000 L000 R000



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- Scroll through Test/Enter screens to verify proper operation. - repeat procedure in REV Direction.

____ 11. Fine Tune Zero location of BEI Encoder for Linear Mode operation. - Pushbuttons on side of PLC Circuit Board can be used momentarily for faster alignment.

Figure 24. Fine Tune Center 0 Degree Location. ____ 12. Verify Tractor Guidance is correct in both FWD and REV directions. - Tractor to left of cable or buried wire, steers back to right. - Tractor to right of cable or buried wire, steers back to left. ____ 13. Fine Tune Above Ground Cable Guidance Controllers or Buried Wire Antennas. - Make sure tractor will follow same tracks in FWD direction and REV direction. ____ 14. Set End Tower Barricades for Right End Tower at each end of run. ____ 15. Perform the Calibration of the Rolling Radius for the Left & Right Ends. See Appendix 1. ____ 16. Set AR/AS Distance Set Points. (See Distance Counter Use in Control Panel section.)

- Hose Drag Linear = Auto Stop only. - Note: If there is more than one hose change location, it is more practical to use the

Primary Safety of the Tractor Guidance or the Position Stop Safety to shut the system down for hose changes or end of run. See Tractor Guidance explanation in later section.

o This will eliminate the need to reset the AR/AS Set Points each time the hose is changed.

o In this case, set the FWD Distance set point to a distance beyond the field edge. This will allow the physical stops to shut the system down.

- Ditch Feed = Auto Stop or Auto Reverse at set distance. ____ 17. Set EG AREAS if applicable. ____ 18. Set AUX APPL Areas if applicable. ____ 19. Perform the Operational Safety Checks described next. ____ 20. Check packing tightness when operated with water to ensure leak free seal.





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3.3. Operational Check of Safeties Wired into PLC Panel Safeties caused by switches wired into PLC Panel, SAFETY CONNS Terminal Block. NOTE: The system must be moving, with the SYSTEM Toggle Switch in the RUN position for the Safety to be logged.

Safety From How to check: SECONDARY Above Cable = Mercury Move so Mercury Switches close. Buried Wire = from Gd Bd Unplug REF Antenna from Gd Bd. - Safety Toggle in PLC Panel in RUN. HYDR OIL LVL Hydr Oil Level Switch - Hydr. Tank In Hydr Tank Panel, jumper Gnd to Term #2 (Orange Wire). HYD OIL PRESS Hydr Oil Press Switch Hydr. Tank Open Manual Bypass Valve on Hydr Tank. (closed below 1500 psi) (Pressure will drop to 0 psi) WATER PRESS Water Press Sw. Gauge Move Water Press Run-Start Sw. on PLC Panel

to RUN without water in system. ENGINE OIL Engine Oil Pressure Gauge Manually Gnd Oil Press. Gauge in Eng Panel. ENGINE TEMP Engine Temp Gauge Manually Gnd Eng Temp Gauge in Eng Panel. POSITN STOP Position Stop Switch Activate Position Stop Switch. AUXILIARY Auxiliary Safety Switch Activate Aux. Safety. Above Ground Cable Gd-

move Control Wand to Primary position - Safety Toggle in PLC Panel in RUN. AUTO STOP AR/AS Switch Activate AR/AS Switch on Right End Tower. OR CURR DIST = SET DIST See later section on Auto Stop/Auto Reverse

by Distance.

3.4. Operational Check of Safeties Generated by PLC Panel Safeties caused by PLC Panel, Setpoint exceeded or reached. NOTE: The system must be moving, with the SYSTEM Toggle Switch in the RUN position for these Safeties to occur.

Safety From How to check: LEFT ET SENS No pulses from Left ET Pull Blue Span Cable wire (#5) from LEFT Sensor Motor for 35 sec. END TOWER Term Block in PLC Panel. RIGHT ET SENS No pulses from Right ET Pull Blue Span Cable wire (#5) from RIGHT Sensor Motor for 35 sec. END TOWER Term Block in PLC Panel. ANALOG WATER Low Analog Water Press. Move Water Press Run-Start Sw. on PLC PRESS (if used) (0-100 psi Sensor) Panel to RUN without water in system. PRIMARY BEI Encoder span angle Set Primary Safety setpoint to 1.0 degree Angle exceeded. - Use pushbuttons on side of PLC Board to

cause angle to move from 0.0 to 1.0 - Set back to 6.0 degrees after test. COMMUNICATION No Comm. with BEI Encoder Disconnect Gn/Wt wire from #5 Comms Term LOST Block in PLC Panel. LOW VOLTAGE Engine Battery voltage Switch PLC Panel Power to OFF with system dropped below 10.5 VDC running.

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4. OPERATION OF SYSTEM - Always have the PLC Panel Power Switch and the Tractor Guidance Safety Switch in the RUN

position, with all other switches on the PLC Panel in the down position when starting the engine. o Unless the Tractor has moved off the Above Cable or Buried Wire, then the Tractor

Guidance Safety Switch must be moved to START to get the system back on track. - Start the diesel engine with the Manual Bypass Valve in the open position. Allow the engine to

come up to speed for a moment, then quickly close the Manual Bypass Valve. - See Engine Drive or Engine Belt Drive Hydraulic Pumping Units - Pivot Operators Manual.

- Check that the Hydraulic Pressure Gauge on the Hydraulic Tank reads 1750 psi. - Once system is operational and moving, all Safety Switches must be in the UP/RUN position.

4.1. Linear Mode General Operation 4.1.1. Make sure stop locations are set.

- Use any combination of stops. End Tower SwitchPosition Stop Switch Distance CounterAbove Cable Primary Stop

500 Ft

Figure 25. Stop Methods.

4.1.2. Set the 0 or 180 Span Position. - In RUN SETUP, Operating Mode is set to Linear, then set the corresponding Span Position: - Spans opposite of Control Panels = 0 Position. - Span above Control Panel = 180 Position. - Distance Counter will always count up in FWD. - Right End Gun Areas might be different in 0 vs 180 position, program accordingly.

Figure 26. Set 0 or 180 Position of Spans.

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4.1.3. Set Zero Position of BEI Encoder. - This may already have been done. - IMPORTANT: Must be done when changing from Pivot Mode back to Linear Mode. - In GUID SETUP, choose Yes then Enter for SET BEI ENCODER TO 0.

4.1.4. Set the Direction and Application of the System. - Set on STATUS Screen 1. - Remember to cycle the System Run-Stop Switch to save any new settings.

4.1.5. Use SYSTEM Toggle Switch to control movement of system. - Set to RUN = start system moving, STOP = stop both end towers. NOTE: Safety Toggle Switch from Tractor Guidance Panel in RUN before moving System

Toggle to RUN. If Tractor Guidance is off track and causing a Safety, move Safety Toggle to Start. Then get Tractor back on the cable or buried wire. Once operational again, have Safety Toggle in RUN before System Toggle to RUN.

4.1.6. Automatic Speed Control of System. 1. SYSTEM Toggle to RUN, or APPL change by operator, or AUX APPL change. 2. Speed information collected for 10 seconds, then ACT Speed displayed 3. Speed adjust occurs at the same time (sends voltage on Term 1& 2, Rt & Lf Ends) a. SET compared to ACT, then speed + or -(larger diff = longer adj time) b. When + or - disappears, another 10 seconds of speed information, etc. 4. Speed change every 10 seconds for 6 times, then every 30 seconds. Gather Speed Info 10 secs. Compare SET vs. ACT, adjust speed. Repeat 10 secs.

4.1.7. All Toggle Switches up (RUN) before leaving the field.

Figure 27. Toggle Switches in RUN.

All Toggle Switches in RUN Position before leaving system unattended.

Water Pressure can be left down if moving DRY.

LEFT SET IPM 018 LEFT ACT IPM 000 RGHT SET IPM 018 RGHT ACT IPM 000


Normal operation, Safety Switch in RUN before placing System Toggle to RUN.

Fig. 26.1. Set Zero Position of Encoder.

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4.1.8. Auto Stop or Auto Reverse of System. 1. By Distance: CURR DIST = SET DIST in travel direction. - see STATUS Screen 2

o System will reverse for 23 seconds. o Then Delay (stop in place) for time set. o Then Shut Down if set to AS, or keep moving

opposite direction if set to AR (Ditch). 2. By End Tower Switch - FWD & REV Setpoints in RUN SETUP should be beyond the reversing locations. - This is so the switch will activate the AS/AR and not the distance setting. IMPORTANT: Ensure placement of Physical Barricades at Field Edge.

o System will reverse for 23 seconds. o Then Delay (stop in place) for time set, AR Delay Screen is displayed. o Then Shut Down if set to AS, or keep moving opposite direction if set

to AR (Ditch).

Figure 28. Auto Reverse Switch

4.2. Linear Mode Hose Drag

4.2.1. Water Shutoff Valve Operation. - Diesel Engine started on ULTRA Tractor, hydraulic pressure to 1750 psi. - Water Valve opens, allows water into system. - Engine Shutdown, Water Valve closes. - Pressure in mainline rises, Water Pump stops from High Pressure shutdown gauge.

Figure 29. Water Shutoff Valve Options.

Hydr Actuated Shutoff Valve

Nelson Valve (Bladder Type)


AR DELAY 03 min TIME LEFT 02:25 02599 ft.

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4.2.2. Couple Hose to Tractor, Plug Other Side.

Figure 30. Hose Connections.

4.2.3. Hose Change Operation.

Figure 31. Hose Change Operation.

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4.3. Linear Mode Ditch Feed 4.3.1. Linear Water Pump Priming and Operation, 12VDC Vacuum Primer.

Note: The Primer Pump automatic oiler should be refilled as needed. Use a light machine oil, detergent free, with a viscosity equivalent to SAE 20 or less.

Note: The Water Pump Oil Lube Reservoir should be filled with T-L Hydraulic Oil.

1. Engine is Off. 2. Suction Screen is in water. 3. Close Butterfly Valve on Discharge of Pump. 4. Open turn Ball Valve plumbed to top of Volute of Pump. 5. Close Knife Switch on Primer. 6. Keep the vacuum pump motor running until water appears in the water trap. 7. Open the knife switch and close the turn Ball Valve. 8. Start the engine, set throttle to speed and open the Butterfly Valve. 9. Fill system with water before increasing engine speed to desired water pressure. 10. For system with rotating suction screen option, adjust the 1/4" needle valve so the screen

rotates slowly; about 2 revolutions per minute.

Figure 32. Priming Pump Operation.

4.3.2. Linear Water Pump Priming and Operation, Hydraulic Motorized Primer. 1. Set End Towers to Stop.

Turn Ball Valve

Knife Switch

Butterfly Valve

Oiler SAE 20

Oil Lube Reservoir (T-L Hydr. Oil)

Water Trap

PLC System Switch to STOP.

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2. Close Butterfly Valve on top of discharge of Cornell Pump. (Shown in Open position.) 3. Start Engine. 4. Close Manual Bypass on Hydraulic Tank to build hydraulic pressure. 5. Open Ball Valve in between Inlet of 6. Open Ball Valve to Hydraulic Motor Diaphragm Pump and inlet of Cornell Pump. so Diaphragm Pump is operating. (shown in Closed position) (shown in Closed position) 7. Depending on length of Suction Pipe, it may take several minutes to prime. 8. When water starts coming out of the OUT port on the Diaphragm Pump, slowly open the

Butterfly Wafer Valve on top of the Cornell Pump. 9. Close the Ball Valve in between Inlet of Diaphragm Pump and inlet of Cornell Pump and close

the Ball Valve to the Hydr. Motor of the Motorized Primer so it stops. (Reverse Steps 5 & 6.) 10. Continue with operation of linear system.

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End Tower Switch

4.4. Pivot Mode Pivoting the Spans IMPORTANT: Do not attempt to Rotate Tractor while in Pivot Mode.

4.4.1. Make sure physical stop location is set in addition to programmed stop location. - Important if structural damage could occur if system traveled

outside of field boundaries.

Figure 33. Set Physical Stop. 4.4.2. Connect Anchor Chains to Tractor.

Figure 34. Anchor Tractor in Pivot Mode.

4.4.3. Set system to PIVOT MODE in RUN SETUP. - Need to tell Panel where system is at and where to travel to.

Set to Pivot Mode and enter Distance to End

Tower Wheel Track. Current Angle will default to the degrees selected

for Span Position of Linear Mode. - Ex. Span Position = 180, set to 180 deg. - Current Angle can be set to any degree. Set Angle to Pivot to, can be set to any degree. Allow use of Overwater Timer in PIVOT MODE - If End Tower gets stuck, degrees wont change If Enabled, enter the Max Time to move 1 Degree - Range = 1 to 90 Minutes.

OPERATING MODE PIVOT DIST TO END TOWER 1000 ft

CURRENT ANGLE 000 deg ANGLE TO PIVOT TO 180 deg

OVERWATER TIMER ENABLE TIME TO MOVE 1 DEG. XX min

12"

24"Diam.

Roughly 1/3 yd. Concrete per Hole

1/2" Re-Bar(Dealer Supplied)

18" 18"

Top of Anchor evenwith ground level.

Earth Anchors- Pivoting Dry

Chains in Concrete- Irrigating while Pivoting

36"

ANCHOR TRACTOR IN PIVOT MODE

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4.4.4. Set Direction and Speed on STATUS Screen 1. - Need to tell system which direction to travel and what speed - Use DIRECTION key to change direction, + and - keys to change APPL.

Figure 35. Pivot Mode.

4.4.5. Use SYSTEM Toggle Switch to control movement of system. - Set to RUN = start Right End moving, set to STOP = Right End tower does not move.

4.4.6. Appropriate Toggle Switches up (RUN) before leaving the field.

Figure 36. Toggle Switch Settings in Pivot Mode.

4.5. Rotation of Tractor for L Shaped Field - Used if irrigating an L-Shaped field in Linear Mode. - IMPORTANT: Operating Mode must be set to LINEAR in order to Rotate Tractor.

Follow the steps in RUN Setup

Rotate Tractor first, then Pivot Spans 90 Degrees.

Figure 37. Procedure to Rotate Tractor.

CCW APPL 45 IPM AS 0.55 48 Hr/Rv EG R 182.5 deg PIVOT TO: 180.0 deg

RUN RUN if watering in Pivot Mode.

RUN

START Tractor Gd

not used.

RUN

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4.5.1. Rotate Tractor Must be in LINEAR Mode.

4.5.2. ENABLE Rotate Ultra Tractor 90 Degrees. - Need to tell Panel where system is at and where to travel to.

Set to ENABLE If ENABLED, more screens will appear. - see following sections.

4.5.3. Set Tractor Wheels into ROTATE position. 1. Jack up Wheel, move to Rotate position. 2. Install Rotation Arm Weldment.

Figure 38. Install Rotation Arm Weldment.

4.5.4. Disengage 2 Gears (Diagonal from each other).

Figure 39. Disengage 2 Gears Diagonal from each other.

ROTATE ULTRA TRACTOR 90 DEGREES DISABLE

WHEELS SET TO ROTATE YES 2 GEARS DISENGAGED YES

A. Remove Cap.

C. Turn clockwise.

B. Push in.

OPERATING MODE LINEAR SPAN POSITION 0 Zero

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Back of Galv Panel. - Forward Coil

toward Nut.

In Yellow Panel. - Forward Coil

toward Nut.

4.5.5. Switch Tractor (Right Side) Direction Coils on Hydraulic Panel. - Remove Coil Nut, switch FORWARD and REVERSE Coil locations.

Jan. 2008 April 2010 May 2010 -

Figure 40. Figure 40.1

4.5.6. Set Guidance out of the way to Rotate if Above Cable or Furrow or Ditch Guidance.

Figure 41.

4.5.7. Tell Panel System is Ready to Rotate. I

4.5.8. Exit RUN SETUP and access STATUS Screen 1. - Operator has 10 minutes to Rotate Tractor before system automatically shuts off. - Unless Operator resets the 10 Minute timeout period.

SWITCH TRACTOR COILS YES TRACTOR GUIDANCE OK YES

READY TO ROTATE YES

Drop Above Cable to Ground.

CW ROTATE AS LEFT ETSEN PRIM REF DSABL L000 R000 IPM 10:00

RIGHT SIDE

RIGHT SIDE

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4.5.9. Set Rotation Direction on STATUS Screen 1. Use DIRECTION Key to toggle 3 Screens CW Rotation CCW Rotation Reset 10 Min. Timeout

4.5.10. Start Tractor Rotating, Then Set Speed. Stop Rotation when Finished. - SYSTEM Toggle Switch to RUN Position. - Use + and - keys to adjust rotation speed of Tractor. - Rotation Speed of about 40 to 60 inches per minute okay. - Speed will show for LEFT End on Status Screen 1. - Right End (far end) of linear system should NOT move. - STOP Rotation using System Toggle Switch. NOTE: If power is turned off or lost during Rotation, the Status screen will be set back to

normal linear operation and Rotate ULTRA Tractor 90 Degrees set to disabled.

4.5.11. Set Tractor Equipment Back to Linear Operation - Reverse steps, backwards from Step 4.5.6 to Step 4.5.2 - Set Tractor Hydraulic Panel Coils back to standard position. - Re-engage Gears. - Remove Rotation Arm Weldment and pin Wheels back in Linear position. - Make sure Guidance is set and ready to operate. - Set Rotate ULTRA Tractor 90 Degrees to DISABLE. - Press RUN SETUP key and ENTER till Rotate ULTRA Tractor 90 Degrees - With DISABLE showing, press ENTER. Or turn off Power to PLC Panel, then back on.

4.5.12. Pivot Spans Perpendicular to Tractor.

Figure 42. Pivot Spans Perpendicular to Tractor.


CCW ROTATE RESET 10 MIN TIMEOUT (ENTER = YES)

CCW ROTATE AS LEFT ETSEN PRIM REF DSABL L000 R000 IPM 10:00


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4.6. Towable Option - The ULTRA Tractor is towable from either side of the Tractor.

WARNING

Towing should be done at the Slowest Speeds Possible and along Smooth Paths. (1-2 mph) Towing across ridges greatly increases the stress on spans and should be avoided. Always be aware of clearance of Overhang Supports. Be especially careful when towing near or under Power Lines. Standard 65 and 85' Overhangs have a 22' support height. Always allow at least 5' clearance before towing under any High Voltage Power Lines.

4.6.1. Set Linear Spans into Tow Position. - Refer to Pivot Operators Manual. - Once spans are in Tow Position, DO NOT operate

the PLC Control Panel.

4.6.2. Set Tractor Guidance. - Position Guidance to allow towing if Above Cable

or Furrow or Ditch Guidance

4.6.3. Disconnect Water Supply Connections.

4.6.4. Prepare Pull Side of Tractor to Tow. - Lift Tower Base and Turn Wheels, Pin Tie Rods in Place - Remove Lock Pin so Hitch can swivel.

Figure 46.

Drop Above Cable to Ground.

Refer to Pivot Operators Manual.

Disconnect Water Supply.

Remove Lock Pin

Fig. 43.

Fig. 44.

Fig. 45.

Operation of System


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4.6.5. Prepare Trailing Side of Tractor to Tow. - Lift Tower Base and Turn Wheels, Pin Tie Rods

in Place. - Keep Lock Pin in place.

Figure 47.

4.6.6. Disengage ALL Gears. - Make sure all gears on the Tractor and

on all Spans are disengaged.

Figure 48.

4.6.7. Adjust Tie Clevis so System Tracks Straight. - Adjust each Tie Clevis on each Wheel. - Adjust on Spans and on Tractor.

Figure 49.

4.6.8. Begin Towing System - Connect Hitch to Tractor Drawbar. - DO NOT JERK SYSTEM. - Tow at slowest uniform speed. - Clear all towers of obstacles. - Tow in straight path.

Figure 50. ULTRA System in Tow Mode.

Trailing Side - Leave Lock Pin in place

Adjust Tie Clevis.

A. Remove Cap.

C. Turn clockwise.

B. Push in.

Operation of System


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4.7. Using ETSEN PRI & REF SFTY - For MOMENTARY operation of the system so it can be moved under any of the following conditions:

a. Left or Right ET Sensor Safety message. b. BEI Encoder Angle Primary Safety

- If this is the only safety, consider temporarily changing the Primary Safety Setting. c. Buried Wire Primary or Reference Safety.

USE WITH CAUTION.

4.7.1. Disable in RUN SETUP

Motorized Flow Control Valves are closed for 35 seconds, then opened for 4 seconds. - In case MFC Valves were wide open.

- When next screen appears, press RUN SETUP to return to Status Screen 1.

4.7.2. SYSTEM Toggle to RUN Position, Operate System - Operator has 10 minutes before ET PRI REF TIMOUT SAFETY occurs. - 10 minute timer can be reset by operator. - 5 different STATUS screens can be toggled through, to change direction and speed. DIRECTION Key + and - Keys - toggles through 5 screens - used to adjust speed of end

displayed on the screen

Screen 1: Fwd, adjust Right End Screen 2: Fwd, adjust Left End Screen 3: Reset 10 Min timer Screen 4: Rev, adjust Right End Screen 5: Rev, adjust Left End

FWD SPD DISABLED RESET 10 MIN TIMEOUT (ENTER = YES)

FWD SPD DISABLED AS RIGHT ETSEN PRIM REF DSABL L052 R043 IPM 06:23

FWD SPD DISABLED AS LEFT ETSEN PRIM REF DSABL L052 R043 IPM 06:23

REV SPD DISABLED AS LEFT ETSEN PRIM REF DSABL L052 R043 IPM 06:23

REV SPD DISABLED AS RIGHT ETSEN PRIM REF DSABL L052 R043 IPM 06:23

Actual speeds shown, if sensors working.

10 min timeout safety timer.

ETSEN PRI & REF SFTY DISABLE

MFC VALVES ADJUSTING WAIT 45 SECONDS

Flashes to let operator know mode.

GUIDANCE OF ULTRA LINEAR


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5. GUIDANCE OF ULTRA LINEAR 5.1. Linear System Guidance

5.1.1. Uses Angle Sensor in Collector Ring - to keep Spans perpendicular to Tractor.

Figure 51. Encoder in Collector Ring. Figure 52. Measure Angle.

5.1.2. Zero BEI Encoder Angle in GUID SETUP

Figure 53 Set Encoder Angle to 0 Degrees.

5.1.3. Keep Connections Tight

Figure 54. Fit-up Snug for Improved Sensitivity.

5.1.4. Alignment Cables Tight, System in Alignment 5.1.4a Check Lower Swivel Elbow Figure 55. Keep Alignment Cables Tight.

Encoder in Collector Ring Measures Angle.

Keep Shims in place and tight.

Nipple tied to fork.

- Set Screw Tight. - Fork snug. - Mounts tight.

See PIVOT OPERATORS MANUAL.

Lower Swivel Elbow should not move.

Gap between Nipple and Fork Bottom.



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5.1.5. Use TEST SCREEN 3 to Monitor System Guidance. - System will steer in response to settings in GUID SETUP. - 2:1 Steering Angle and 3:1 Steering Angle, and Anti-Oversteer settings. Examples: Spans in 0 Zero Position

Figure 56. System Guidance 0 Position

Examples: Spans in 180 Position

Figure 57. System Guidance 180 Position

5.1.6. Excessive Angle will Push or Pull Tractor. - Angle of Spans should stay under 2.0 degrees - Fluid in Tires, Extra Weight on Tractor may be necessary to stabilize the Tractor. - May have to change to Pivot Mode to straighten system out.

Figure 58. Excessive Angle.

FWD ANGLE 00.5 deg * 0 00.0 SPANS AHEAD SET018 L024 R012

FWD ANGLE 00.5 deg * 180 00.0 SPANS AHEAD SET018 L024 R012



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5.2. Tractor Guidance Overview 5.2.1. Hydraulic Circuit.

Figure 59. Hydraulic Circuit.

5.2.2. Hydraulic Control Panel Circuit

Jan. 2008 April 2010 Galvanized Hydraulic Panel

Figure 60. Tractor Hydraulic Panel.

2

1

3

4 5

6



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May 2010 - Yellow Hydraulic Manifold Panel

Figure 60.1 Tractor Hydraulic Manifold Panel Assy.

5.2.3. Oil Flow Path Oil into PORT 1, filtered -> MFC sets speed -> Flow Divided into 4 equal parts -> Steering Solenoids direct oil to each side of tractor -> Direction Control Valves determine Fwd or Rev -> Left side oil to PORTS 2 & 3, Right side oil to PORTS 4 & 5 -> Return to Tank PORT 6. Steering Solenoids: Neither energized = 2 parts oil to Right Side, 2 parts to Left side = 1:1 Steer Lft Sol energized = 1 part from Left back to flow divider = 2:1 Steer (Left slow) Rt Sol energized = 1 part from Right back to flow divider = 1:2 Steer (Right slow)

5.2.4. Steering - Keeps Tractor on straight Path.

- Steers Tractor by changing speeds of tires on each side.

Figure 61. Tractor Guidance Operation.

2

1

3

4

5

6

Steering

Direction



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Normal operation, 1st move Safety Switch to RUN. 2nd move System Toggle to RUN.

Placing Safety Switch in RUN after System

Toggle to RUN will cause a false safety.

5.3. Tractor Guidance Above Ground Cable (See Section 6.9 for Troubleshooting of Above Cable Tractor Guidance.

Refer to CD90462 Linear Hose Drag Operators Manual for complete explanation.)

5.3.1. Components

Figure 61. Above Ground Controller. Figure 62. Tractor Guidance Panel.

5.3.2. Proximity Controller Operation

Figure 63. Proximity Controller Operation.

5.3.3. SAFETY & SYSTEM Toggle Switches

Figure 63.1. Toggle Switches in RUN.

Guidance Controllers Wired to Tractor Guidance Panel.

May 2010 on: ET Circuit Bd not in this panel. Bd is in Hydr Panel.



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5.3.4. Linear Logic Board in Tractor Guidance Panel - Refer to CD90462 Linear Hose Drag Operators Manual for complete explanation.

Figure 64. Linear Logic Board.

5.3.5. Use of Components - Set Above Cable Pos. Stop Rods (1) to deflect Guidance Wands (2) into a Primary Safety -

condition of the Logic Bd in the Tractor Gd. Panel (5). - Primary Safety Tractor Guidance = Prox Switches not seeing metal. - Make sure Safety Toggle Switch (7) in PLC Panel (6) is set to RUN.

PanelTract. Gd.

PLCPanel

RUN

SAFETY

START

5

6 7

ABOVE GROUND GUIDANCE- SAFETY STOPS

Pos. StopAbove Cable

Pos. StopAbove Cable

Stop SafetyLinear Pos.

Tee Post

1

1

2

23

4

Figure 65. Above Ground Cable Components.



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5.4. Tractor Guidance Buried Wire - NOTE: Engine will NOT stay running if low or no Oscillator signal, see Section 6.10 Troubleshooting. - PLC Panel POWER switch must be in the RUN position when starting the engine. Hold 117 in for

5 seconds after engine starts. - Refer to CD90462 Linear Hose Drag Operators Manual for complete explanation.

5.4.1. Buried Wire Guidance Components

Figure 66. Buried Wire Guidance Components.

5.4.2. Buried Wire Guidance Tractor Panel - Guidance Board must be installed and receiving good Reference Antenna signal.

- If not, Secondary Safety will occur on PLC Panel.

Figure 67. Buried Wire Tractor Panel. Figure 68. Buried Wire Guidance Board.

5.4.3. Use of Components - Set Position Stop Tee posts at ends of hose pull. - Make sure Safety Toggle Switch in PLC Panel is set to RUN. - If Guidance Board PRI or SEC light is on, see Troubleshooting Section.

Buried WireTractor Panel

HydraulicPanel

PLCPanel

PositionStop

TeePost

ReverseSteeringAntenna

AntennaSteeringForward

ReferenceAntenna

RUN lit = all okay.

SEC lit = low or no signal.

PRI lit = off track.

May 2010 on: ET Circuit Bd not in this panel. Bd is in Hydr Panel.

Troubleshooting


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6. TROUBLESHOOTING If you need help with a problem, please have the following information ready for your dealer:

- Serial Number, Hose Drag or Ditch Feed, Above Cable or Buried Wire Guidance

6.1. Safety Messages Switches Wired to PLC Engine May Die when 117 Released. Safeties caused by switches, components wired into PLC Panel: NOTE: Engine may not stay running, even with PLC Panel in OFF if one of these are safetied.

Safety Cause Checks SECONDARY A. Above Cable Tractor Gd A.1. Check for Gnd on Term 1 of - Mercury Tilt Switch SAFETY CONNS Block. B. Buried Wire Tractor Gd B.1. Gnd on Yw Wire from Tractor Pnl - Low Ref Sig. to Gd Bd to Term 1 of SAFETY CONNS block. B.2. Check Ref. Ant. Signal & Osc Sig. B.3. Check Gd Bd installed in Tractor Pnl. B.4. Check Safety Relay energized in Tractor Pnl. HYDR OIL LVL A. Hydr Oil Level Switch in A.1. Check for Gnd on Term 2 of Hydr. Tank SAFETY CONNS Block. HYD OIL PRESS A. Hydr Oil Press Switch in A.1. Check for Gnd on Term 3 of Hydr. Tank (1500 psi) SAFETY CONNS Block. A.2. Check Hydr Press Run-Start Sw. WATER PRESS A. Water Press Sw. Gauge A.1. Check for Gnd on Term 4 of SAFETY

CONNS Block. A.2. Check Water Press Run-Start Sw. ENGINE OIL A. Engine Oil Pressure Gauge A.1. Check for Gnd on Term 5 of SAFETY

CONNS Block. ENGINE TEMP A. Engine Temp Gauge A.1. Check for Gnd on Term 6 of SAFETY

CONNS Block. POSITN STOP A. Position Stop Switch A.1. Check for Gnd on Term 7 of SAFETY CONNS Block. AUXILIARY A. Buried Wire Tractor Gd A.1. Gnd on Be/Bk Wire from Tractor Pnl - Primary Safety to Term 8 of SAFETY CONNS block. A.2. Check Steering Ant

ULTRA Linear Operators Manual

Documents

linear system guidance

linear mode

linear components

tractor guidance

linear operators manual

rotation of tractor

keypad operation

control panel overview