ULTRA Linear Operators Manual

Irrigation Company
Hastings, Nebraska
ULTRA Linear System

OPERATION AND
TROUBLESHOOTING MANUAL
CD90461
January 2011
PLC Vers. 0.4.16 to 0.4.20
T L
1.
Table of Contents
INTRODUCTION......................................................................................................................................... 5
1.1.
General Information ........................................................................................................................................... 5
1.1.1.
Qualified Operators .................................................................................................................................. 5
1.1.2.
Maintenance ............................................................................................................................................. 5
1.2.
Guidelines for System Operation ....................................................................................................................... 5
1.3.
ULTRA Linear Components .............................................................................................................................. 6
1.4.
ULTRA Linear System Operation Modes Overview........................................................................................... 6
1.4.1.
Linear Mode.............................................................................................................................................. 6
1.4.2.
Pivot Mode................................................................................................................................................ 7
1.4.3.
0 Zero Position vs. 180 Position of Spans ........................................................................................... 7
1.4.4.
Rotation of Tractor for L-Shaped Field ..................................................................................................... 7
1.4.5.
Towable Option ........................................................................................................................................ 8
1.5.
Linear System Guidance Notes (See Section 5.1) ............................................................................................ 8
1.5.1.
System Guidance - keeps spans perpendicular to the Tractor ................................................................. 8
1.5.2.
Tractor Guidance - keeps Tractor on straight path ................................................................................... 9
1.5.3.
Storage of Rotation Arm and Tie Rod ..................................................................................................... 10
2.
CONTROL PANEL ................................................................................................................................... 11

2.1.
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 ............................................................................................................................................. 20
2.14.1.
Distance Counter Explanation ................................................................................................................ 20
2.14.2.
Distance Counter Use Set to Auto Stop or Auto Reverse .................................................................... 20
2.14.3.
Distance Counter Use AUX APPL ....................................................................................................... 21
2.15.
3.
4.
Example Programming .................................................................................................................................... 21
INITIAL START-UP OF SYSTEM ............................................................................................................ 23

3.1.
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
OPERATION OF SYSTEM ....................................................................................................................... 28

4.1.
Linear Mode General Operation ................................................................................................................... 28
4.1.1.
Make sure stop locations are set. ........................................................................................................... 28
4.1.2.
Set the 0 or 180 Span Position. ......................................................................................................... 28
4.1.3.
Set Zero Position of BEI Encoder. .......................................................................................................... 29
1/25/2011
ULTRA Linear Operators Manual
T L
4.1.4.
4.1.5.
4.1.6.
4.1.7.
4.1.8.
Table of Contents
Set the Direction and Application of the System. .................................................................................... 29
Use SYSTEM Toggle Switch to control movement of system. ............................................................... 29
Automatic Speed Control of System. ...................................................................................................... 29
All Toggle Switches up (RUN) before leaving the field. .......................................................................... 29
Auto Stop or Auto Reverse of System. ................................................................................................... 30
4.2.
Linear Mode Hose Drag................................................................................................................................ 30
4.2.1.
Water Shutoff Valve Operation. .............................................................................................................. 30
4.2.2.
Couple Hose to Tractor, Plug Other Side. .............................................................................................. 31
4.2.3.
Hose Change Operation. ........................................................................................................................ 31
4.3.
Linear Mode Ditch Feed ............................................................................................................................... 32
4.3.1.
Linear Water Pump Priming and Operation, 12VDC Vacuum Primer. .................................................... 32
4.3.2.
Linear Water Pump Priming and Operation, Hydraulic Motorized Primer. .............................................. 32
4.4.
Pivot Mode Pivoting the Spans ..................................................................................................................... 34
4.4.1.
Make sure physical stop location is set in addition to programmed stop location. .................................. 34
4.4.2.
Connect Anchor Chains to Tractor.......................................................................................................... 34
4.4.3.
Set system to PIVOT MODE in RUN SETUP. ........................................................................................34
4.4.4.
Set Direction and Speed on STATUS Screen 1. .................................................................................... 35
4.4.5.
Use SYSTEM Toggle Switch to control movement of system. ............................................................... 35
4.4.6.
Appropriate Toggle Switches up (RUN) before leaving the field. ............................................................ 35
4.5.
Rotation of Tractor for L Shaped Field .......................................................................................................... 35
4.5.1.
Rotate Tractor Must be in LINEAR Mode. ........................................................................................... 36
4.5.2.
ENABLE Rotate Ultra Tractor 90 Degrees. .......................................................................................... 36
4.5.3.
Set Tractor Wheels into ROTATE position. ............................................................................................ 36
4.5.4.
Disengage 2 Gears (Diagonal from each other). .................................................................................... 36
4.5.5.
Switch Tractor (Right Side) Direction Coils on Hydraulic Panel. ............................................................. 37
4.5.6.
Set Guidance out of the way to Rotate if Above Cable or Furrow or Ditch Guidance. ............................ 37
4.5.7.
Tell Panel System is Ready to Rotate. ................................................................................................... 37
4.5.8.
Exit RUN SETUP and access STATUS Screen 1................................................................................... 37
4.5.9.
Set Rotation Direction on STATUS Screen 1. ........................................................................................ 38
4.5.10.
Start Tractor Rotating, Then Set Speed. Stop Rotation when Finished. ................................................ 38
4.5.11.
Set Tractor Equipment Back to Linear Operation ................................................................................... 38
4.5.12.
Pivot Spans Perpendicular to Tractor. .................................................................................................... 38
4.6.
Towable Option ............................................................................................................................................... 39
4.6.1.
Set Linear Spans into Tow Position. ....................................................................................................... 39
4.6.2.
Set Tractor Guidance.............................................................................................................................. 39
4.6.3.
Disconnect Water Supply Connections................................................................................................... 39
4.6.4.
Prepare Pull Side of Tractor to Tow. .................................................................................................... 39
4.6.5.
Prepare Trailing Side of Tractor to Tow. ............................................................................................... 40
4.6.6.
Disengage ALL Gears. ........................................................................................................................... 40
4.6.7.
Adjust Tie Clevis so System Tracks Straight. ......................................................................................... 40
4.6.8.
Begin Towing System ............................................................................................................................. 40
4.7.
Using ETSEN PRI & REF SFTY ...................................................................................................................... 41
4.7.1.
Disable in RUN SETUP ........................................................................................................................ 41
4.7.2.
SYSTEM Toggle to RUN Position, Operate System ............................................................................... 41
5.
GUIDANCE OF ULTRA LINEAR .............................................................................................................. 42

5.1.
Linear System Guidance ................................................................................................................................. 42
5.1.1.
Uses Angle Sensor in Collector Ring ...................................................................................................... 42
5.1.2.
Zero BEI Encoder Angle in GUID SETUP .............................................................................................. 42
5.1.3.
Keep Connections Tight ......................................................................................................................... 42
5.1.4.
Alignment Cables Tight, System in Alignment 5.1.4a Check Lower Swivel Elbow ................................ 42
5.1.5.
Use TEST SCREEN 3 to Monitor System Guidance. ............................................................................. 43
5.1.6.
Excessive Angle will Push or Pull Tractor. .............................................................................................. 43
5.2.
Tractor Guidance Overview .......................................................................................................................... 44
5.2.1.
Hydraulic Circuit...................................................................................................................................... 44
5.2.2.
Hydraulic Control Panel Circuit ............................................................................................................... 44
5.2.3.
Oil Flow Path .......................................................................................................................................... 45
5.2.4.
Steering .................................................................................................................................................. 45
1/25/2011
Table of Contents
T L
5.3.
Tractor Guidance Above Ground Cable ....................................................................................................... 46
5.3.1.
Components ........................................................................................................................................... 46
5.3.2.
Proximity Controller Operation................................................................................................................ 46
5.3.3.
SAFETY & SYSTEM Toggle Switches ................................................................................................... 46
5.3.4.
Linear Logic Board in Tractor Guidance Panel ....................................................................................... 47
5.3.5.
Use of Components ................................................................................................................................ 47
5.4.
Tractor Guidance Buried Wire ...................................................................................................................... 48
5.4.1.
Buried Wire Guidance Components ....................................................................................................... 48
5.4.2.
Buried Wire Guidance Tractor Panel ...................................................................................................... 48
5.4.3.
Use of Components ................................................................................................................................ 48
6.
TROUBLESHOOTING ............................................................................................................................. 49
6.1.
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 ............................................................................................. 70
6.9.1.
General Overview ................................................................................................................................... 70
6.10.
Buried Wire Tractor Guidance Troubleshooting .............................................................................................. 71
6.10.1.
General Overview ................................................................................................................................... 71
6.10.2.
Guidance Board Indicator LEDs. ........................................................................................................... 72
6.10.3.
Low or No Oscillator Signal. ................................................................................................................... 72
6.10.4.
Guidance Board PRI LED on. .............................................................................................................. 73
6.11.
Tractor Pushed or Pulled off Guidance............................................................................................................ 73
6.11.1.
Excessive Angle will Push or Pull Tractor. .............................................................................................. 73
6.12.
BEI Encoder Not Reading. .............................................................................................................................. 73
6.12.1.
Check Wiring of BEI Encoder. ................................................................................................................ 73
6.12.2.
Check Jumpers on PLC Bd and RX1 LED. ............................................................................................ 74
6.12.3.
Check Power and Signal Lines. .............................................................................................................. 74
7.
APPENDIX 1: CALIBRATION OF ROLLING RADIUS .......................................................................... 75
8.
APPENDIX 2: WIRING DIAGRAMS ....................................................................................................... 77

8.1.
Cable Routing (Jan. 2008 April 2010).......................................................................................................... 77
8.2.
Cable Routing (May 2010 -
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 -
8.7.
Above Ground Guidance Tractor Panel Wiring (Jan. 2008 April 2010) ....................................................... 83
8.8.
Above Ground Guidance Tractor Panel Wiring (May 2010 -
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 -
1/25/2011
)................................................................................................................... 78
) ............................................................................ 82
) ............................................................... 84
) ..................................................................... 87
T L
9.
Table of Contents
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 -
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
) ............................................................... 90
APPENDIX 3: Service Parts ................................................................................................................... 95
10. APPENDIX 4: Set-Up Records ............................................................................................................... 96
1/25/2011
Introduction
T L
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.
1/25/2011
Introduction
T L
1.3. ULTRA Linear Components
ULTRA TRACTOR
RIGHT END TOWER

Collector Ring
with Encoder
Tractor Guidance
Control Panel
End Tower
Manifold
Precision Linear
Control Panel (PLC)
Tractor Hydraulic
Control Panel
Auto Stop/
Reverse Assy
May 2010 change to

Yellow Panel
(Manifold Assy).
Engine
Panel
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).
Forward
- facing controls.
- to the Left.
Figure 2. Linear Mode Operation.
Reverse
- facing controls.
- to the Right.
Figure 3. Ultra Tractor in Linear Mode.
1/25/2011
Introduction
T L
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.
1/25/2011
Introduction
T L
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.
Encoder in
Collector Ring
Measures Angle.
Figure 9. Encoder in Collector Ring.
Figure 10. Measure Angle.
- Keep fit-up tight for improved sensitivity.

Keep Shims in
place and tight.
Nipple tied
to fork.
- Set Screw Tight.

- Fork snug.
- Mounts tight.
Figure 11. Fit-up Snug for Improved Sensitivity.
1/25/2011
Introduction
T L
- Make sure Jumpers are in place on the back of the PLC Board and that RX1 is flashing.
RX1 LED
flashing
Jumpers on
J6 and
J8.
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.
1/25/2011
Introduction
T L
- 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
TIE ROD
(TOW OPTION)
ROTATION
ARM
Figure 16. Storage Location for Rotation Arms and Tie Rods.
10
1/25/2011
T L
Control Panel
2. CONTROL PANEL
2.1. Control Panel Overview
1
FWD APPL
AS
0.75
STEERING = L1:R2
7
2
Figure 17. Control Panel Overview.
Backlit LCD Screen:
Backlighting turns off after 2 minutes of no key presses. Press any

key to turn backlighting on.
Keypad:
12 Keys for operator use. See explanations following for more detail.
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.)
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.)
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.
Water Pressure Switch:
RUN = Analog Water Pressure and Switch Gauge active.

START = Ignore Water Pressure safeties, run system dry.
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.)
1/25/2011
11
Control Panel
T L
2.2. Board Power Up and Keypad Operation
T-L IRRIGATION
Title Screen
Safety Message
(after safety shutdown)
Status Screen 1
(default screen)
PRECISION LINEAR
CONTROL
V4.11
FIRMWARE VERSION
MUST BE 0.4.11 or later.
(03.1 or earlier will NOT
work with ULTRA.)
AUTO STOP SAFETY

THR 11/30/06 10:58A
(Press Enter)
FWD APPL
AS
0.75
STEERING = L1:R2
Press Key to
access function.
Press Key again
to exit.
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.
DIRECTION Key
- Toggles FWD & REV
+ & - Keys
- Adjust Appl. in 0.05
increments.
Test Screen 1 shows speed.

SET IPM
LEFT SENSOR
RIGHT SENSOR
018
*
*
Figure 19. Setting System Speed and Direction.
12
1/25/2011
T L
Control Panel
2.4. STATUS Key

Press STATUS key to advance through screens.
STATUS SCREEN 1
STATUS SCREEN 2
STATUS SCREEN 3
FWD APPL 0.75

AS
EG L R
STEERING = L1:R1
AO
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
Line 1 = Direction, Application

Line 2 = Auto Stop or Auto Rev
Line 3 = End Guns On (if used)
Line 4 = Steering Status
(AO shown if in Anti-Oversteer)
Line 1 = Current Date & Time

Line 2 = Dist. to AS or AR
Line 3 = Current Position
Line 4 = Time to Set Dist
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)
TUE
01/24/06
12:52:43 P
RUN TIMES
CURR
USER
TOTAL
SET DATE
SET TIME
SET AM/PM
HR:M:S
00013:29:41
00106:07:13
01890:52:58
12/25/04
SUN
12:01
P
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.
UNITS
English
IRRIGATED WIDTH
01300
Ft
1/25/2011
English or Metric
Distance to End + EG Throw
13
Control Panel
T L
WATER SUPPLY
Hose Drag
WATER FLOW
0800
GPM
Hose Drag or Ditch Feed
LEFT (TRACTOR) GEAR

68:1
LEFT (TRACTOR) TIRE
23.5
In Roll Radius
Gear Ratio of Left End (Tractor)
RIGHT GEAR
68:1
RIGHT TIRE
23.5
In Roll Radius
Gear Ratio of Right End
MAX SPD
MIN APPL
Enter Max Speed of System

60 IPM (152 cm/min) unless noted otherwise
- MIN APPL will be calculated.
060 IPM
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
14
Water Flow to Linear (GPM or l/sec)
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
Rolling Radius of Right Tire

NOTE: Adjust Rolling Radius of Right & Left.
See Calibration of Rolling Radius.
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
LOW WATER PRESS

12 PSI
0:30 m:s
INITIAL TIME
15:00
If Analog Water Pressure:

- Safety set point pressure and time
Initial Time = time it takes to build
water pressure at startup.
WATER FLOW METER

Yes
IF YES
1.25 GAL/PULSE
Yes or No
LINEAR TYPE
Ultra
Ultra or Single Tower Tractor

- Ultra Tractor has 2 sets of towers and a
swivel pivot point.
Gal. per Pulse from flowmeter
1/25/2011
T L
Control Panel
2.7. EG AREAS Key

Press EG AREAS Key to access this function, press again to return to STATUS screen.
NOTE: Consider End Gun Areas with Spans in 180 Position will they be used? DISABLE?
EG AREAS
ENABLE
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
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:

RT END GUN AREA 1
XXX.X To XXX.X deg
RT END GUN AREA 2
XXX.X To XXX.X deg
2.8. AUX APPL Key

Press AUX APPL Key to access this function, press again to return to STATUS screen.
AUX APPL
ENABLE
Enable or Disable
If Disable, following screens not shown
FWD AUX1 APPL 0.00

000 IPM
FWD AUX1 APPL RANGE
00000 ft To 00000 ft
1st Application rate change in FWD

(if used)
st
Range for 1 Appl change in FWD
(Set low to high, ex. 500 to 1000)
FWD AUX2 APPL 0.00

000 IPM
FWD AUX2 APPL RANGE
00000 ft To 00000 ft
Application rate change in FWD

(if used)
Range for 2nd Appl change in FWD
(Set low to high, ex. 1500 to 2000)
nd
REV AUX1 APPL 0.00

000 IPM
REV AUX1 APPL RANGE
00000 ft To 00000 ft
REV AUX2 APPL 0.00
000 IPM
REV AUX2 APPL RANGE
00000 ft To 00000 ft
1/25/2011
st
1 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)
15
T L
Control Panel
2.9. GUID SETUP Key

Press GUID SETUP Key to access this function, press again to return to STATUS screen.
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.)
GUIDANCE TYPE
BEI Serial 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
STEERING SIG TIME

004 secs.
STAY STEERING TIME
012 secs
Time Steering Signal must be present

before changing steering ratios.
Time to remain steering once
steering has been changed.
SET BEI ENCODER TO 0

NO
IF YES
Press Enter at 0 deg
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.
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
16
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.
1/25/2011
T L
Control Panel
ANTI OVRSTR BACK OUT

1.0 Deg
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.
AR/AS SET POINTS

FWD =
10000 ft.
REV =
00000 ft.
AR/AS DELAY 00 Min
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:
DITCH FEED
AUTO REVERSE DIR.
FWD
FWD, REV, BOTH, or NEITHER

Direction to Auto Reverse if Ditch Feed
(Default is AS, unless told to AR)
Continue here:
RE-SET DISTANCE
NO.
IF YES
00000 ft.
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

NOT ALLOWED:
DISTANCE GREATER
THAN FWD AR/AS
SET-POINT
CURR DIST cannot be reset to distance

greater than FWD SET DIST
NOT ALLOWED:
DISTANCE LESS
THAN REV AR/AS
SET-POINT
CURR DIST cannot be reset to distance

less than REV SET DIST
Continue here:
RESET USER RUN
TIME TO ZERO
NO
1/25/2011
Yes or No
Resets the USER TIME displayed
on DATE/TIMES Screen 2 to 0000:00:00.
17
T L
Control Panel
Enable or Disable
Allows disabling of Safeties so operator
can temporarily run (10 minute timeout)
- See following section
ETSEN PRI & REF SFTY

ENABLE
If ETSEN PRI & REF SFTY set to Disabled, the following screen shows:
MFC VALVES ADJUSTING
WAIT 45 SECONDS
(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
OPERATING MODE
LINEAR
SPAN POSITION
0 Zero
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:

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
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
18
END TO USE FOR

DISTANCE COUNTER
Right
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.
LOW POWER SAFETY

ENABLE
Enable or Disabled (v 0.1.W on)

If Enabled, occurs if 12VDC Power falls
below 10.8 VDC. SYSTEM toggle in RUN.
ROTATE ULTRA TRACTOR

90 DEGREES
DISABLE
Default is DISABLE.
If ENABLE, see ROTATION of TRACTOR section.
Operating Mode must be LINEAR to Rotate
Tractor.
1/25/2011
T L
Control Panel
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 IPM
Set Travel Speed for selected Appl. Rate
018
LEFT SENSOR
RIGHT SENSOR
LEFT SET IPM

LEFT ACT IPM
RGHT SET IPM
RGHT ACT IPM
*
*
012
014
024
022
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:

FWD ANGLE
00.5 deg *
0
00.0
SPANS BEHIND
SET018 L018 R018 AO
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.
S1
S2
PRIMARY SAFETY
04/30/08 11:22A
AUTO STOP SAFETY
04/18/08 8:48P
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
1/25/2011
19
Control Panel
T L
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.
DITCH FEED
AUTO REVERSE DIR.
FWD
AR/AS SET POINTS

FWD =
2600 ft.
REV =
00000 ft.
AR/AS DELAY
05 Min
Step 3. RUN SETUP = Reset Current

Distance (current location).
Step 4. STATUS Screen 1 = Set Direction

& Appl. Rate. Start moving.
FWD APPL
AS
RE-SET DISTANCE
YES.
IF YES
00500 ft.
0.75
STEERING = L1:R1
Step 5. STATUS Screen 2 = View

Set & Curr Distance.
(If Dir. set to FWD)
WED 7/29/08 10:23A
SET DIST=02600 ft
CURR DIST=00500 ft
013:42:16 TO STOP
20
(If Dir. set to REV)

WED 7/29/08 10:23A
SET DIST=00000 ft
CURR DIST=00500 ft
004:01:09 TO STOP
1/25/2011
T L
Control Panel
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 AUX2 APPL 0.50
028 IPM
REV AUX2 APPL RANGE
00600 ft To 00000 ft
REV AUX1 APPL 0.75

021 IPM
REV AUX1 APPL RANGE
02000 ft To 00600 ft
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.
1/25/2011
21
Control Panel
T L
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.)
1300 ft
600 ft
REV
Rev Aux1
0.75 in
Off
600 ft
0 ft
REV
Rev Aux2
0.50 in
Off
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
Water Supply
Setting
Hose Drag
RUN SETUP
Item
AR/AS Setpoint FWD
AR/AS Setpoing REV
AR/AS Delay Timer
Re-Set Distance
Enter Distance
Re-Set User Run Time to Zero
ETSEN Pri & Ref Sfty
Operating Mode
Span Position
End to Use for Distance Counter
Rotation of Tractor
Setting
2650
0
5
Yes
10
______
Enable
Linear
0 Zero
Right
Disable
Choices/Units
Choices/Units
ft (programmed beyond so AR/AS Switch stops it)
ft
min.
(System is at home location)
ft (So AR/AS switch stops it in REV, & not 0 ft)
Yes/No (User Preference)
(Left End on Hose Drag = slippage, not accurate)
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
22
1700 ft
To
2600 ft
1/25/2011
T L
Initial Start-Up of System
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
Screen 1
Screen 2
Screen 3
Setting
N/A
N/A
______
Choices/Units
Display current date & time, Hr:Min:Sec
Display the Run Times
Enter date (mm/dd/yy), day, time and AM or PM
SYSTEM SETUP (defaults)

Item
Units
Irrigated Width
Water Supply
Water Flow
Left (Tractor) Gear
Left (Tractor) Tire
Right Gear
Right Tire
Max Speed
Min Appl.
Spd Adj Rate Left
Spd Adj Rate Right
Analog Water Pressure
Full Scale
Low Water Press
Initial Delay
Water Flow Meter
Gal/Pulse
Linear Type
Example
English
1285
Hose
800
68:1
23.5
68:1
23.5
60
.20
.018
.018
Yes
100
12
00:30
15:00
Yes
1.25
ULTRA
Setting
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
Choices/Units
English or Metric
Ft
GPM
IPM
in.
sec/IPM
sec /IPM
Yes/No
0 to 200 (Max Pressure on 4 to 20 mA sensor)
psi
mm:ss
mm:ss
Yes/No
EG AREAS
EG AREAS
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
1/25/2011
Enable/Disable
Setting
RT EG Area 1
_______deg To _______deg
RT EG Area 2
_______deg To _______deg
23
T L
AUX APPL
AUX APPL
Item
Enable/Disable
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
Guidance Type
BEI Encoder
Steering Sig Time
4
Stay Steering Time
12
Set BEI Angle to 0
Press Enter at 0
2:1 Steering Angle
0.5
3:1 Steering Angle
1.0
Primary Safety Level
6.0
Anti Ovrstr Out
1.0
Anti Ovrstr In
1.0
Anti Ovrstr Back Out
1.0
Setting
BEI
______
______
______
Choices/Units
Above Cable SRH280 or Buried Wire
sec
sec
Yes/No (Set to 0 degrees at startup)
______
______
______
______
______
______
deg
deg
deg
deg
deg
deg
Setting
______
______
______
______
______
______
______
______
______
______
______
______
______
Choices/Units
ft
ft
min.
FWD, REV, Both, NEITHER
Yes/No,
ft
Yes/No
Enable/Disable
Linear/Pivot
0 or 180
Left or Right
Enable/Disable
Yes/No
RUN SETUP
Item
AR/AS Setpoint FWD
AR/AS Setpoing REV
AR/AS Delay Timer
Ditch Feed Auto Reverse (if Ditch)
Re-Set Distance
Enter Distance
Operating Mode
Span Position (Linear Mode)
End to use for Distance Counter
Low Power Safety
Rotate Tractor 90 Degrees
24
1/25/2011
T L
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.
FWD ANGLE
00.0 deg *
0
00.0
CENTER
SET000 L000 R000
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.
1/25/2011
25
T L
- Scroll through Test/Enter screens to verify proper operation.

SET IPM
024
LEFT SENSOR
RIGHT SENSOR
*
*
LEFT SET IPM

LEFT ACT IPM
RGHT SET IPM
RGHT ACT IPM
012
014
036
034
- 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.
26
1/25/2011
T L
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
SECONDARY
From
Above Cable = Mercury
Buried Wire = from Gd Bd
How to check:
Move so Mercury Switches close.
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

(closed below 1500 psi)
Open Manual Bypass Valve on Hydr Tank.

(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 Gdmove Control Wand to Primary position
- Safety Toggle in PLC Panel in RUN.
AR/AS Switch
CURR DIST = SET DIST
Activate AR/AS Switch on Right End Tower.

See later section on Auto Stop/Auto Reverse
by Distance.
AUTO STOP
OR
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.
1/25/2011
Safety
LEFT ET SENS
From
No pulses from Left ET
Sensor Motor for 35 sec.
How to check:
Pull Blue Span Cable wire (#5) from LEFT
END TOWER Term Block in PLC Panel.
RIGHT ET SENS
No pulses from Right ET

Pull Blue Span Cable wire (#5) from RIGHT

END TOWER Term Block in PLC Panel.
ANALOG WATER
PRESS (if used)
Low Analog Water Press.

(0-100 psi Sensor)
Move Water Press Run-Start Sw. on PLC

Panel to RUN without water in system.
PRIMARY
BEI Encoder span angle

Angle exceeded.
Set Primary Safety setpoint to 1.0 degree

- 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
LOST
No Comm. with BEI Encoder
Disconnect Gn/Wt wire from #5 Comms Term

Block in PLC Panel.
LOW VOLTAGE
Engine Battery voltage

dropped below 10.5 VDC
Switch PLC Panel Power to OFF with system

running.
27
Operation of System
T L
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.
Above Cable Primary Stop
Position Stop Switch
End Tower Switch
Distance Counter
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.
28
1/25/2011
T L
Operation of System
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.
Fig. 26.1. Set Zero Position of Encoder.
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.
LEFT SET IPM
LEFT ACT IPM
RGHT SET IPM
RGHT ACT IPM
4.1.7.
018
000
018
000
Compare SET vs. ACT, adjust speed. Repeat 10 secs.

LEFT SET IPM
LEFT ACT IPM
RGHT SET IPM
RGHT ACT IPM
018
020
018
016
All Toggle Switches up (RUN) before leaving the field.
All Toggle Switches in RUN

Position before leaving
system unattended.
Water Pressure can be left

down if moving DRY.
Normal operation, Safety

Switch in RUN before placing
System Toggle to RUN.
Figure 27. Toggle Switches in RUN.
1/25/2011
29
Operation of System
T L
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).
WED 7/29/08 10:23A

SET DIST=02600 ft
CURR DIST=02600 ft
000:00:00 TO STOP
AR DELAY 03 min
TIME LEFT 02:25
02599 ft.
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.
Nelson Valve
(Bladder Type)
Hydr Actuated
Shutoff Valve
Figure 29. Water Shutoff Valve Options.
30
1/25/2011
T L
Operation of System
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.
1/25/2011
31
Operation of System
T L
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.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Engine is Off.
Suction Screen is in water.
Close Butterfly Valve on Discharge of Pump.
Open turn Ball Valve plumbed to top of Volute of Pump.
Close Knife Switch on Primer.
Keep the vacuum pump motor running until water appears in the water trap.
Open the knife switch and close the turn Ball Valve.
Start the engine, set throttle to speed and open the Butterfly Valve.
Fill system with water before increasing engine speed to desired water pressure.
For system with rotating suction screen option, adjust the 1/4" needle valve so the screen
rotates slowly; about 2 revolutions per minute.
Butterfly
Valve
Water
Trap
Oil Lube
Reservoir
(T-L Hydr. Oil)
Oiler
SAE 20
Knife
Switch
Turn
Ball Valve
Figure 32. Priming Pump Operation.
4.3.2.
Linear Water Pump Priming and Operation, Hydraulic Motorized Primer.

1. Set End Towers to Stop.
PLC
System
Switch to
STOP.
32
1/25/2011
T L
Operation of System
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

Diaphragm Pump and inlet of Cornell Pump.
(shown in Closed position)
6. Open Ball Valve to Hydraulic Motor

so Diaphragm Pump is operating.
(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.
1/25/2011
33
Operation of System
T L
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 End Tower Switch
outside of field boundaries.
Figure 33. Set Physical Stop.

4.4.2.
Connect Anchor Chains to Tractor.

ANCHOR TRACTOR IN PIVOT MODE
Earth Anchors
- Pivoting Dry
Chains in Concrete
- Irrigating while Pivoting
Top of Anchor even

with ground level.
18"
12"
18"
Roughly 1/3 yd.

Concrete per Hole
36"
24"
Diam.
1/2" Re-Bar
(Dealer Supplied)
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.
OPERATING MODE
PIVOT
DIST TO END TOWER
1000 ft
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.
CURRENT ANGLE
000 deg
ANGLE TO PIVOT TO
180 deg
OVERWATER TIMER
ENABLE
TIME TO MOVE 1 DEG.
XX min
34
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.
1/25/2011
T L
Operation of System
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.
CCW APPL
AS
0.55
EG R
PIVOT TO:
45 IPM
48 Hr/Rv
182.5 deg
180.0 deg
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.

RUN
RUN
RUN if watering
in Pivot Mode.
RUN
START
Tractor Gd
not used.
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.
1/25/2011
35
T L
4.5.1.
Operation of System
Rotate Tractor Must be in LINEAR Mode.

OPERATING MODE
LINEAR
SPAN POSITION
0 Zero
4.5.2.
ENABLE Rotate Ultra Tractor 90 Degrees.

- Need to tell Panel where system is at and where to travel to.
ROTATE ULTRA TRACTOR

90 DEGREES
DISABLE
4.5.3.
Set to ENABLE
If ENABLED, more screens will appear.

- see following sections.
Set Tractor Wheels into ROTATE position.

1. Jack up Wheel, move to Rotate position.
2. Install Rotation Arm Weldment.
WHEELS SET TO ROTATE
YES
2 GEARS DISENGAGED
YES
Figure 38. Install Rotation Arm Weldment.
4.5.4.
Disengage 2 Gears (Diagonal from each other).

C. Turn clockwise.
B. Push in.
A. Remove Cap.
Figure 39. Disengage 2 Gears Diagonal from each other.
36
1/25/2011
T L
Operation of System
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 In Yellow Panel.

- Forward Coil
toward Nut.
Back of Galv Panel.

- Forward Coil
toward Nut.
RIGHT SIDE
RIGHT
SIDE
Figure 40.
Figure 40.1
SWITCH TRACTOR COILS

YES
TRACTOR GUIDANCE OK
YES
4.5.6.
Set Guidance out of the way to Rotate if Above Cable or Furrow or Ditch Guidance.
Drop Above Cable

to Ground.
Figure 41.
4.5.7.
Tell Panel System is Ready to Rotate.

READY TO ROTATE
YES
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.
CW
ROTATE
AS
LEFT
ETSEN PRIM REF DSABL
L000 R000 IPM
10:00
1/25/2011
37
T L
4.5.9.
Operation of System
Set Rotation Direction on STATUS Screen 1.

Use DIRECTION Key to toggle 3 Screens
CW Rotation
CW
ROTATE
AS
LEFT
L000 R000 IPM
10:00
CCW Rotation
CCW
ROTATE
AS
LEFT
L000 R000 IPM
10:00
Reset 10 Min. Timeout

CCW
ROTATE
RESET 10 MIN TIMEOUT

(ENTER = YES)
4.5.10. Start Tractor Rotating, Then Set Speed. Stop Rotation when Finished.
- SYSTEM Toggle Switch to RUN Position.
CW
ROTATE
- Use + and - keys to adjust rotation speed of Tractor.
AS
LEFT
- Rotation Speed of about 40 to 60 inches per minute okay.
- Speed will show for LEFT End on Status Screen 1.
L055 R000 IPM
08:47
- 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.
38
1/25/2011
T L
Operation of System
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.
Refer to Pivot
Operators Manual.
4.6.2.
Fig. 43.
Set Tractor Guidance.

- Position Guidance to allow towing if Above Cable
or Furrow or Ditch Guidance
Fig. 44.
Drop Above Cable

to Ground.
4.6.3.
Disconnect Water Supply Connections.

Fig. 45.
Disconnect Water
Supply.
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.
Remove
Lock Pin
Figure 46.
1/25/2011
39
T L
4.6.5.
Operation of System
Prepare Trailing Side of Tractor to Tow.

- Lift Tower Base and Turn Wheels, Pin Tie Rods
in Place.
- Keep Lock Pin in place.
Trailing Side
- Leave 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.
C. Turn clockwise.
B. Push in.
A. Remove Cap.
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.
Adjust
Tie
Clevis.
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.
40
1/25/2011
T L
Operation of System
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

DISABLE
MFC VALVES ADJUSTING

WAIT 45 SECONDS
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
- toggles through 5 screens
Screen 1:
Fwd, adjust Right End
FWD
SPD DISABLED
AS
RIGHT
L052 R043 IPM
06:23
Screen 2:
FWD
SPD DISABLED
AS
LEFT
L052 R043 IPM
06:23
Fwd, adjust Left End
Screen 3:
Reset 10 Min timer
1/25/2011
+ and - Keys
- used to adjust speed of end
displayed on the screen
FWD
Flashes to let operator

know mode.
Actual speeds shown,

if sensors working.
10 min timeout
safety timer.
SPD DISABLED
RESET 10 MIN TIMEOUT

(ENTER = YES)
Screen 4:
Rev, adjust Right End
REV
SPD DISABLED
AS
RIGHT
L052 R043 IPM
06:23
Screen 5:
Rev, adjust Left End
REV
SPD DISABLED
AS
LEFT
L052 R043 IPM
06:23
41
GUIDANCE OF ULTRA LINEAR
T L
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.
Encoder in
Collector Ring
Measures Angle.
Figure 51. Encoder in Collector Ring.
5.1.2.
Figure 52. Measure Angle.
Zero BEI Encoder Angle in GUID SETUP
Figure 53 Set Encoder Angle to 0 Degrees.
5.1.3.
Keep Connections Tight
Keep Shims in
place and tight.
Gap between
Nipple and
Fork Bottom.
Nipple tied
to fork.
- Set Screw Tight.

- Fork snug.
- Mounts 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
See PIVOT
OPERATORS MANUAL.
Lower Swivel Elbow
should not move.
Figure 55. Keep Alignment Cables Tight.

42
1/25/2011
T L
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
FWD ANGLE
00.5 deg *
0
00.0
SPANS AHEAD
SET018 L024 R012
Figure 56. System Guidance 0 Position
Examples: Spans in 180 Position

FWD ANGLE
00.5 deg *
180
00.0
SPANS AHEAD
SET018 L024 R012
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.
1/25/2011
43
T L
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
1
Figure 60. Tractor Hydraulic Panel.
44
1/25/2011
T L

May 2010 -
Yellow Hydraulic Manifold Panel
Direction
Steering
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.
1/25/2011
45
T L
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
May 2010 on:
ET Circuit Bd not in
this panel. Bd is in
Hydr Panel.
Guidance Controllers
Wired to Tractor
Guidance Panel.
Figure 61. Above Ground Controller.

5.3.2.
Figure 62. Tractor Guidance Panel.
Proximity Controller Operation
Figure 63. Proximity Controller Operation.
5.3.3.
SAFETY & SYSTEM Toggle Switches

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.
Figure 63.1. Toggle Switches in RUN.
46
1/25/2011
T L
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.
SAFETY
6 PLC
Panel
Above Cable
Pos. Stop
RUN
START
5
Tract. Gd.
Panel
Linear Pos.
Stop Safety
3
Tee Post
1
Above Cable
Pos. Stop
4
ABOVE GROUND GUIDANCE
- SAFETY STOPS
Figure 65. Above Ground Cable Components.
1/25/2011
47
T L
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.
5.4.1.
Buried Wire Guidance Components
Forward
Steering
Antenna
Reverse
Steering
Antenna
Buried Wire
Tractor Panel
PLC
Panel
Hydraulic
Panel
Reference
Antenna
Position
Stop
Tee
Post
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.
RUN lit =
all okay.
PRI lit = SEC lit = low

off track. or no signal.
May 2010 on:

ET Circuit Bd not in
this panel. Bd is in
Hydr Panel.
Figure 67. Buried Wire Tractor Panel.

5.4.3.
48
Figure 68. Buried Wire Guidance Board.
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.
1/25/2011
T L
Troubleshooting
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

- Mercury Tilt Switch
B. Buried Wire Tractor Gd
- Low Ref Sig. to Gd Bd
A.1. Check for Gnd on Term 1 of

SAFETY CONNS Block.
B.1. Gnd on Yw Wire from Tractor Pnl
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

Hydr. Tank

SAFETY CONNS Block.
HYD OIL PRESS
A. Hydr Oil Press Switch in

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

SAFETY CONNS Block.
AUXILIARY
A. Buried Wire Tractor Gd

- Primary Safety
A.1. Gnd on Be/Bk Wire from Tractor Pnl

to Term 8 of SAFETY CONNS block.
A.2. Check Steering Ant Signal level.
B.1. Check for Gnd on Term 8 of
SAFETY CONNS Block.
B. Auxiliary Safety Switch
AUTO STOP
A. AR/AS Switch
OR
1/25/2011
B. CURR DIST = SET DIST
A.1. Check for +24 VDC on Term 7 of

LEFT & RIGHT END TOWER block.
B.1. Check settings in RUN SETUP.
49
T L
Troubleshooting
6.2. Safety Messages Caused by PLC Quick Reference

Safeties caused by PLC Panel, Setpoint exceeded or reached:
Safety
LEFT ET SENS
(more info following)
Cause
A. No pulses from Left ET
Checks
A.1. Check Circuit Bd in Tractor Pnl for
SENS PWR & SPD SIG.
A.2. Check Term 5 of LEFT END TOWER
Block in PLC for pulses.
A.3. Check back of PLC Bd for LED
SPD PULSE.
RIGHT ET SENS
A. No pulses from Right ET

A.1. Check Circuit Bd in ET Manifold for

SENS PWR & SPD SIG.
A.2. Check Term 5 of RIGHT END TOWER
Block in PLC for pulses.
A.3. Check back of PLC Bd for LED
SPD PULSE.
ANALOG WATER PRESS
A. Low Analog Water Press.

(0-100 psi Sensor)
A.1. Check settings in SYSTEM SETUP.

A.2. Check Water Pressure reading on
STATUS SCREEN 3.
A.3. Check Water Press Run-Start Sw.
PRIMARY
A. System Guidance - Angle

of Encoder exceeded.
A.1.
A.2.
A.3.
A.4.
COMMUNICATION LOST
A. No Comm with Encoder

in Coll. Ring.
A.1. Check wiring of Encoder.

A.2. Check jumpers in place on back of
PLC Panel.
ETSEN PRI REF TIMEOUT A. ETSEN PRI REF SFTY

Disabled in RUN SETUP
Check setting in GUID SETUP

Check Angle reading Test Screen 3
Spans too far ahead or behind tractor.
Spans in180 pos. check Test Screen 3.
A.1. 10 min. time out once disabled, but

timer can be reset. See Operation.
LOW VOLTAGE
A. Engine Battery voltage

A.1. Check +12 IN Orange wire in J12
dropped below 10.5 VDC
Power Connector to PLC Bd.
with SYSTEM toggle in RUN.
OVERWATER SAFETY
A. Pivot Mode Angle did not A.1. Check setting in RUN SETUP.
increase or decrease 1 deg. A.2. Check if End Tower is stuck.
in set time.
A.3. Check speed of system vs. setting.
A.4. Check for loose connections, if
encoder is actually rotating.
6.3. Other Problems Quick Reference

Problem
End Tower keeps moving with SYSTEM in STOP.
End Tower will not move with SYSTEM in RUN.
NOTE: If the system Auto Reverses, it will move for
23 secs. regardless of SYSTEM Switch
End Tower speed will not adjust
50
Cause/Checks
Check Direction Control Cartridge and MFC
Cartridge. (more info following)
Check MFC (Motorized Flow Control)

1/25/2011
T L
Troubleshooting
6.4. PLC Control Panel Circuit Board

IMPORTANT:
1. PLC Circuit Board MUST BE Rev. 5, with 256 processor to operate ULTRA.
2. Jumpers must be installed on J6 & J8 to enable communication with Encoder.
LED Indicators
- Left and Right Speed Pulses
- Speed Adjustment Left and Right
- Increase +, Decrease -
- Auxiliary Speed Switch 1 or 2
- CPU (flashing = working correctly)
- +24 VDC Power
- +5 VDC Power
Direction Override Pushbuttons

Momentary Direction Change of
End Towers
- Red = Right REV, Left FWD
- White = Right FWD, Left REV
Ribbon Connectors
Keypad &
LCD Screen
Fuses
F2 = Lf MFC A
F4 = Lf MFC B
F3 = Rt MFC A
F5 = Rt MFC B
(all above 0.5A
slow acting.)
Battery
CR2032
- for Date/Time
256
Relay LEDs
D23 = FWD, Lf
D24 = REV, Lf
D27 = FWD,Rt
D28 = REV, Rt
D31 = EG, Lf
D32 = EG Rt
D35 = Safety
F1=+24VDC IN
5A
Rev 5
D88 = Water Flow
Pulses
D81 = Rev Sw.
COM LEDs
Jumpers J6 & J8
ULTRA Encoder
Safety
Connector
Com1, Com2
Connector
Above Str
Pots
Left End
Connector
Right End
Connector
Analog
Connector
Power
Connector
Figure 69. PLC Circuit Board Overview
1/25/2011
51
T L
Troubleshooting
6.5. Right End Tower Control Manifold Components
Figure 70. Right End Tower Control Manifold Components.
6.6. Point Manifold PCB (Printed Circuit Board)

Observe the LEDs on the Point Manifold PCB to tell what is happening at the end tower.
Figure 71. Point Manifold PCB
52
1/25/2011
T L
Troubleshooting
6.7. Tractor Hydraulic Panel Components (Left End)

- Oil Flow Path described in section 5.2.3.
Figure 72. Tractor Hydraulic Panel (Jan. 2008 April 2010).
1/25/2011
53
T L
May 2010 -
Troubleshooting
Direction
Steering
BOTTOM
VIEW
Figure 72.1 Tractor Hydraulic Manifold Panel Assy (May 2010 -
54
).
1/25/2011
T L
Troubleshooting
6.8. Tractor Control Panels Electric & Hydraulic

Buried Wire Guidance Board
Above Cable Logic Board
Steering Control
- Above Ground or
Buried Wire
TRACTOR STEERING
CONTROL CIRCUIT
12VDC
SPEED & DIRECTION

CONTROL CIRCUIT
24VDC
Sensor Motor
- used to determine
speed of the tractor.
Steering Solenoids
- set 1:1 steer or 2:1 steer
Flow Divider
- divides flow into 4 equal parts
MFC (Motorized Flow Control)

- sets speed of Tractor.
Tractor Direction Control

- Right Side Direction

- Left Side Direction
Figure 73. Tractor Hydraulic Panel (Jan. 2008 April 2010).
1/25/2011
55
Troubleshooting
T L
May 2010 -

Above Cable Logic Board
Buried Wire Guidance Board
Steering Control
- Above Ground or
Buried Wire
TRACTOR STEERING
CONTROL CIRCUIT
12VDC
MFC (Motorized Flow Control)

- sets speed of Tractor.
Flow Divider
- divides flow into 4 equal parts

- Left & Right Side Direction
SPEED & DIRECTION

CONTROL CIRCUIT
24VDC
Steering Solenoids
- set 1:1 steer or 2:1 steer
Sensor Motor
- used to determine
speed of the tractor.
Figure 73.1. Tractor Hydraulic Panel (May 2010 56
).
1/25/2011
T L
Troubleshooting
Direction Coils to be Energized PIVOT MODE

LEFT END - TRACTOR
= No Coils energized in
Pivot Mode
RIGHT END TOWER

MANIFOLD
Status Screen #1
CCW APPL
AS
0.55
EG R
PIVOT TO:
CCW = FWD Coil
45 IPM
48 Hr/Rv
302.5 deg
180.0 deg
CW = REV Coil
CCW = FWD LED

= +24 on #3
= Red Wire
CW = REV LED
= +24 on #4
= Orange Wire
Figure 73.1 Pivot Mode.
May 2010 -
Direction Coils to be Energized LINEAR MODE, 0 POSITION
RIGHT END TWR MANIFOLD
Test Screen #3
= Verify 0 Position
FWD ANGLE
00.5 deg *
0
00.0
SPANS AHEAD
SET018 L024 R012
FWD = FWD Coil

LEFT END - TRACTOR
REV = REV Coil
FWD LED
= +24 on #3
= Red Wire
FWD LED
= +24 on #3
= Red Wire
= FWD Coils
REV LED
= +24 on #4
= Orange Wire
= REV Coils
REV LED
= +24 on #4
= Orange Wire
May 2010 -
Figure 73.2 Linear Mode 0 Position.
1/25/2011
57
Troubleshooting
T L
Direction Coils to be Energized LINEAR MODE, 180 POSITION

Notes to remember about the 180 position:
- Spans are now on the opposite side of the tractor.
- Fwd and Rev are still determined by facing the Control Panels.
- The LEFT End is always the Tractor
- The RIGHT End is the End Tower.
- Directions coils on the Right End are energized opposite of the 0 position.
LEFT END - TRACTOR

FWD LED
= +24 on #3
= Red Wire
= FWD Coils
Test Screen #3
= Verify 180 Position
REV LED
= +24 on #4
= Orange Wire
= REV Coils
FWD ANGLE
00.5 deg *
180
00.0
SPANS AHEAD
SET018 L024 R012
May 2010 -
RIGHT END TWR MANIFOLD
REV = FWD Coil

FWD =REV Coil
REV= FWD LED

= +24 on #3
= Red Wire
FWD = REV LED

= +24 on #4
= Orange Wire
Figure 73.3 Linear Mode 180 Position.
58
1/25/2011
T L
Troubleshooting
System Will Not Move in One Direction Check Coils

Check for proper voltage (24 VDC) at the End Tower.
NOTE: Voltage MUST BE at least 22 VDC for the Direction Solenoid to work properly.
Forward, check between terminals 3 and 8 (ground)
Reverse, check between terminals 4 and 8 (ground).
Figure 74. Check End Tower Solenoid Coils
System Will Not Stop or System Will Not Move in One Direction
Check Solenoid Valve Cartridge
Note: Direction Control Cartridge Valve Change Jan. 2008
Prior to Jan. 2008 = Gold Cartridge
Jan. 2008 and after = Silver Cartridge (Coils opposite)
If the system will not stop when it should or if both coils can be removed and the system continues to walk;
the 4-Way DC Valve Cartridge may be contaminated. The same is true if the system will move one direction,
but not the other.
- Use one coil to check operation in both directions as shown
Remove the coils from the Valve Cartridge and then remove the Cartridge from the Body by unscrewing it.
Examine the ports for contamination. Blow the ports out, preferably with compressed air. Try to work the
plunger, which is located inside the cartridge and can be accessed from the bottom of the cartridge.
The cartridge can be separated for contamination removal. The bottom portion will unscrew from the top
portion. The threads have been sealed with lock-tight. Using 2 pairs of vise grips on the cartridge will allow
more force with less possibility of scarring. Hold the top with a 7/8 wrench.
1/25/2011
59
T L
Troubleshooting
Figure 75. Check End 4-Way Solenoid Cartridge
System Will Not Move in Either Direction Possible Reasons

Hydraulic reasons:
- No Hydraulic system pressure
- Pressure Line Ball Valve at End Tower is closed
- End Tower Filter is Plugged
- DC Valve Cartridge is stuck, will not change position
Electrical reasons:
- No 24VDC power to End Tower Coils
- MFC (Motorized Flow Control) cartridge is in fully closed position
System Will Not Move in Either Direction Check 160 WATT Power Supply
Figure 76. Power Supply Check - Engine Drive
60
1/25/2011
T L
Troubleshooting
System Will Not Move in Either Direction Check Motorized Flow Control (MFC)
Speed Change Operation - Explanation
1. SYSTEM Toggle to RUN position, or + - APPL change.
2. Speed Pulses counted for 10 seconds, then ACT Speed displayed on Test Screen 2
3. Speed change made (sends voltage on Term 1& 2, Right & Left Ends)
- SET compared to ACT, speed + or - accordingly.
- the farther apart the SET is from ACT, the longer + or - will show.
- LEDs on PLC Board and End Tower Board indicate Speed Change (SPD+ or SPD-)
- Either +24VDC or -24VDC, depending on if speed needs to be increased or decreased.
- Test Screen 2 shows + or to indicate change is taking place, and whether increase or decrease.
LEFT SET IPM
LEFT ACT IPM
RGHT SET IPM
RGHT ACT IPM
024
030
024
020
4. At end of Speed Change, Speed Pulses again counted for 10 secs.

5. Speed adjustment process repeated 6 times, with 10 second intervals.
6. Then adjustment interval is changed to 30 seconds.
Figure 77. Check Motorized Flow Control.
NOTE: To manually adjust the speed of the End Towers using the Keypad, Disable the ETSEN PRI & REF
SFTY. See OPERATION section for full explanation. This allows for easier voltage checks.
DISABLE
1/25/2011
61
T L
Troubleshooting
Manually Adjust Speed Using MFC at End Tower, System Moving Either FWD or REV
Figure 78. Manually Operate Motorized Flow Control (MFC) at End Tower.
Remove Motorized Flow Control at End Tower for Visual Check
Figure 79. Manually Operate Motorized Flow Control at End Tower.
62
1/25/2011
T L
Troubleshooting
Intermediate Tower in Bypass, ET Sensor Safety

NOTE: Use Caution, refer to Pivot Operators Manual.
Option 1: End Tower movement not needed to re-align:
1. Leave SYSTEM Run-Stop Toggle Switch in STOP of Precision Linear Panel.
2. Start Hydraulic Pump, safety switches to Start position.
3. Re-align tower, use Precision Linear Panel and operate normally.
Option 2: End Tower movement desired as tower is re-aligned:
Refer to following section on RIGHT or LEFT ET SENS SAFETY.
RIGHT ET SENS SAFETY or LEFT ET SENS SAFETY (Actual Speed Displays 0)

-
Precision Linear Control Board not receiving pulses from the End Tower Speed Sensor
for 35 secs. with System switch in the RUN position,
Possible causes:
- The End Tower may be stopped. No movement of the End Tower to provide pulses.
- The End Tower may be moving but the Speed Sensor is defective.
- There may be a loose wire, a wiring problem or no power to the Speed Sensor.
First make checks at Panel:
Figure 79.1. Check Speed Sensor Operation at PLC Panel.
If No Pulses at Panel, Disable the ETSEN PRI & REF SFTY
Figure 80. Disable ETSEN PRI & REF SFTY.
1/25/2011
63
T L
Troubleshooting
End Tower Speed must be slowed down for End Tower Checks.
Figure 81. Slow End Tower Speed to 6-10 IPM.
Use Volt Meter to Check Sensor Power and Sensor Pulses at End Tower.
Figure 82. Check Sensor Power and Pulses.
If still not correct, remove Bk Pulse Wire in Sensor Cable from ET Manifold PCB Bd.
Figure 83. Check Sensor Pulses with Bk Wire Disconnected.
64
1/25/2011
T L
Troubleshooting
Results of Testing
- If no power to Spd Sensor, determine why.
- If Pulse Voltage is present, but low side not below 1.0 VDC, see Grounding Notes.
- If Pulse Voltage is good with Bk Wire disconnected (Test #8), but not correct with Bk Wire
connected in circuit, then Pulse Voltage shorted somewhere.
- Try bypassing the Manifold PCB, connect Bk Pulse wire directly to Blue Span Wire.
- Check Span Wire to PLC Panel.
- If Pulse Voltage is not good with Bk Wire disconnected (Test #8), then problem is in either the
Sensor Cable or Sensor itself.
- Use Sensor Tester as follows.
Grounding Notes:
Figure 84. Check Grounds.
Use Sensor Tester
Figure 85. Use Sensor Tester.
1/25/2011
65
T L
Troubleshooting
T-L Sensor Tester (EA532180) Notes:
Make sure that End Tower is moving 6 - 10 IPM.

Press the Battery Test button on tester before connecting to sensor.
o LED on top of Tester should light.
Sensors that are not installed can be tested by connecting sensor to Tester and then placing
Ferrous metal (screwdriver, pliers, etc) next to sensing face of sensor. Then move back and forth
across the face of sensor to simulate motor shaft teeth going by sensor.
Speed Sensor Replacement

If Speed Sensor does not generate pulses with +24 power to the sensor, it will need to be replaced using the
following procedure:
1.
Remove existing speed sensor wires from end tower junction box OR if separate yellow cable
comes off sensor, unscrew cable from sensor
2.
Unscrew existing speed sensor from hydraulic motor.
3.
Install new speed sensor.
- turn speed sensor in till it bottoms out on shaft (do NOT force)
(be sure jam nut is backed off sufficiently)
- back speed sensor out at least turn CCW plus the amount
necessary to align the notches. Notches on speed
sensor hex nut must end up perpendicular to motor shaft.
- back speed sensor out only enough to align notch (at least turn)
- hold in place and tighten jam nut.
- Parker Sensor motors do not require alignment
NOTE: If the Speed Sensor at the End Tower is defective or pulses are not received by the Precision Linear
Board, the Board will see this as the Linear not moving and thus keep trying to increase the speed of the
Linear until the ET Sensor Safety occurs. (0 IPM actual vs. Set speed)
Figure 86. Speed Sensor Replacement
66
1/25/2011
T L
Troubleshooting
End Gun Not Working

1. Check Wiring, Voltages, Coil Ohms, and LEDs on Circuit Bds.
Figure 87. End Gun Operation Checks
2. Check Proper operation at End Tower

- proper voltage to End Gun Coil (+24 VDC)
- ohm the Coil (40 ohms)
- Nut should be on FINGER TIGHT (3 ft. lbs. torque)
- remove the Cartridge and check for contamination
- separate top from bottom as explained earlier for the Direction Solenoid
Figure 88. Check End Gun Solenoid
1/25/2011
67
Troubleshooting
T L
3. Check Operation of Cylinder Shutoff Valve:
Figure 88.1 Check End Gun Solenoid.
Figure 88.2 Check End Gun Booster Solenoid.
68
1/25/2011
T L
Troubleshooting
Checking Auto Reverse/Auto Stop Operation

If the Auto Reverse/Auto Stop does not operate correctly, determine if the problem is hydraulic or electrical.
A quick check is to check that the direction coils are being activated correctly for the desired direction (see
previous sections). If the coils are activated correctly, but the system will not change direction, the problem is
more than likely hydraulic and probably contamination in the directional control solenoid valve cartridge.
If the coils are not switching, the problem can be assumed to be electrical. Use the following diagram to trace
the Auto Reverse Operation.
Figure 89. Check Auto Reverse/Auto Stop Operation.
1/25/2011
69
Troubleshooting
T L
6.9. Above Cable Tractor Guidance Troubleshooting

-
Refer to CD90462 Linear Hose Drag Operators Manual for complete explanation.
Refer to Appendix 2 for Wiring Diagram
6.9.1.
General Overview
Tractor Gd
Elec Panel
Reverse
Controller
Hydraulic
Panel
Secondary
Safety
Position
Stop
Forward
Controller
12VDC Safety Relay (Jan. 2011)

- Primary Safety or Proc Safety
from Logic Board closes Relay
and sends Ground on term 7
Be/Bk wire to PLC Panel.
Above Ground Cable Gd.

- energizes steering valves
to keep tractor moving
straight down the cable.
24VDC Reversing Relay

- +24 to Relay, closes
Reverse Circuit on Logic Bd.
- tells Logic Board to use the
Reverse Controller.
Panels shown:
Jan. 2008 April 2010.
See Fig 73.1
May 2010 -
Figure 90. Above Ground Cable Guidance Overview.
70
1/25/2011
T L
Troubleshooting
6.10. Buried Wire Tractor Guidance Troubleshooting

- Refer to Appendix 2 for Wiring Diagram
6.10.1. General Overview
DUMMY LOAD METER Checks:
Ref Antenna = 10.0 mVAC
Str Antenna = 0.0 mVAC over wire
0.2 mVAC to steer
0.8 mVAC Primary Sfty
Forward
Steering
Antenna
Reverse
Steering
Antenna
Tractor Gd
Elec. Panel
Tractor Gd
Hydr. Panel
Reference
Antenna
Buried Wire Gd.

- energizes steering valves
to keep tractor moving
straight down the cable.
Check Guidance Bd.

- no jumpers installed
- Switch to LINEAR
Safety Relay
- Stops system if Guidance
Bd is removed.
- +24 to Relay, keeps Gnd
circuit open and no Safety
with Gd Bd in place.
Panels shown:
Jan. 2008 April 2010.
See Fig 73.1
May 2010 -
Figure 91. Buried Wire Overview.
1/25/2011
71
T L
Troubleshooting
6.10.2. Guidance Board Indicator LEDs.

RUN
PRI
SEC
Figure 92. LEDs on Guidance Board.

6.10.3. Low or No Oscillator Signal.
- Engine will NOT stay running, with PLC Panel Power RUN:
- Guidance Bd not installed in Tractor Gd Panel
- Low or No Oscillator Signal.
- Disconnect Yw/Bk wire connected to SAFETY CONNS Term 1.
- Check if SEC light is lit on Gd Bd.
- SEC = low or no Reference Antenna Signal
- RUN = all okay
Figure 93. Buried Wire Troubleshooting.
72
1/25/2011
T L
Troubleshooting
6.10.4. Guidance Board PRI LED on.

- System is off the wire, trying to steer back on track.
- Move Safety Toggle Switch in PLC Panel to START to correct the problem.
6.11. Tractor Pushed or Pulled off Guidance

6.11.1. 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 94. Excessive Angle.
6.12. BEI Encoder Not Reading.

- System Toggle Switch in RUN position, COMMUNICATION LOST safety.
6.12.1. Check Wiring of BEI Encoder.
Figure 95. Wiring of Serial Encoder.
1/25/2011
73
T L
Troubleshooting
6.12.2. Check Jumpers on PLC Bd and RX1 LED.

RX1 LED
flashing
Jumpers on
J6 and
J8.
Figure 96. Check PLC Board.
6.12.3. Check Power and Signal Lines.

- In PLC Panel, check power to Encoder
- In PLC Panel, check with TTL meter on 2 comm wires
Figure 97. Check Encoder Power and Signal.
74
1/25/2011
T L
APPENDIX 1
7. APPENDIX 1: CALIBRATION OF ROLLING RADIUS

Step 1. Operate System at 1:1 steering ratio. End tower speed set
about 40 IPM. Operate so Left and Right ACT IPM are
about equal. Stop system.
LEFT SET IPM

LEFT ACT IPM
RGHT SET IPM
RGHT ACT IPM
040
040
040
040
Step 2. Disconnect MFC adjustment wires to Left and Right Ends.

- this will allow system to travel at set IPM, without any changes.
Figure 98. Disconnect Left & Right MFC wires

Step 3. Flag 100 ft on both the Left and Right ends. System can travel either FWD or REV. FWD shown.
Figure 99. Flag out 100 ft and time how long it takes each end to Travel.
Step 4. Place SYSTEM Toggle in RUN position. Time how long it takes for each end to travel the 100 ft.
- use a Stop Watch or use the CURR TIME from the PLC. This must be exact.
Step 5. Calculate the measured IPM and compare to the LEFT & RIGHT ACT IPM from Test Screen.
Then adjust the RR for the Left & Right Ends in SYSTEM SETUP.
Example:
Left time = 27 min 54 sec
Right Time = 27 min 10 sec
Meas. IPM = 43
Meas. IPM = 44
Left ACT = 40
Right ACT = 40
% diff = 7.5%
% diff = 10%
LEFT RR = 22.9 in
RIGHT RR = 22.9 in
Adjust by 1.7 in
Adjust by 2.3 in
New LEFT RR = 24.6
New RIGHT RR = 25.2
Example Calculations:
Distance (ft) X 12 in/ft
Meas. IPM = ------------------------------------(min X 60 sec/min) + sec
X 60 sec/min
100 ft X 12 in/ft
Ex. Left Meas. IPM = -------------------------- X 60
(27 X 60) + 54
1/25/2011
72000
------------------ = 43 IPM
secs in 100 ft
75
APPENDIX 1
T L
43 - 40
Ex. % diff = ------------- X 100
40
Ex. Adjust = 22.9 X 0.075 = 1.7 in
7.5%
New LEFT RR = 22.9 + 1.7 = 24.6 in
(NOTE: If measured IPM is high, increase RR.
If measured IPM is low, decrease RR.)
Check Distance Counter

- Once the RR for the Left & Right Tires has been calibrated, the distance counter should be
accurate. Use the following procedure to check. Remember that the Distance Counter uses the
Right End for calculation.
Repeat the above procedure for Calibration of RR.
This time, also check the distance counter before and after
traveling 100 ft. (Status Screen 2.)
Example before = 150 ft.
Example after = 251 ft.
THU 11/29/07 10:23A

SET DIST=01320 ft
CURR DIST=00150 ft
005:42:16 TO STOP
THU 11/29/07 10:53A

SET DIST=01320 ft
CURR DIST=00251 ft
005:42:16 TO STOP
Net Distance traveled = 101 ft. vs. 100 meas.
Distance Checkpoints
Establish distance checkpoints at known, measured distances, such as:
- hose change locations
- Application change locations (Aux Appl setpoints)
- crop change locations
- End Gun setpoints
- etc.
Compare the checkpoint distance with the CURR DIST displayed on STATUS SCREEN 2.
- If off by more than 2%, repeat procedure for Calibration of RR.
- reset Distance in RUN SETUP to match location.
Figure 100. Establish Distance Checkpoints
76
1/25/2011
T L
APPENDIX 2
8. APPENDIX 2: WIRING DIAGRAMS

8.1. Cable Routing (Jan. 2008 April 2010)
Collector
Ring
Span
Cable
Reverse
Controller
20/15
(Gray)
14/2
16/8
Secondary
Safety
Position
Stop
Forward
Controller
Tract.
Gd.
Panel
14/2
16/8
16/10
Str. Coils
Hydr.
Tank
PLC
Panel
16/4
16/8
Engine
Panel
Sensor
Cable
Hydr.
Panel
Dir. Coils
& MFC
Collector
Ring
Span
Cable
Reverse
Antenna
20/15
(Gray)
Position
Stop
Forward
Antenna
Tract.
Gd.
Panel
14/2
16/10
Str. Coils
Hydr.
Tank
PLC
Panel
16/4
16/8
Engine
Panel
Sensor
Cable
Hydr.
Panel
Dir. Coils
& MFC
Reference
Antenna
Figure 101. Cable Routing (Jan. 2008 April 2010).
1/25/2011
77
APPENDIX 2
T L
8.2. Cable Routing (May 2010 -
)
Collector
Ring
Span
Cable
Reverse
Controller
20/15
(Gray)
14/2
16/8
Secondary
Safety
Position
Stop
Forward
Controller
14/2
16/8
16/10
Hydr.
Panel
Hydr.
Tank
PLC
Panel
Tract.
Gd.
Panel
16/4
16/8
Engine
Panel
Sensor
Cable
16/10
Collector
Ring
Span
Cable
Reverse
Antenna
20/15
(Gray)
Position
Stop
Forward
Antenna
14/2
16/10
Hydr.
Panel
Hydr.
Tank
PLC
Panel
Tract.
Gd.
Panel
16/10
16/4
16/8
Engine
Panel
Sensor
Cable
Reference
Antenna
Figure 101.1 Cable Routing (Jan. 2008 April 2010).
78
1/25/2011
T L
APPENDIX 2
8.3. Precision Linear Control Panel Internal Wiring Top Half vers 4 & 5 Bd
Figure 103. Precision Linear Control Panel Internal Wiring Top Half vers 4 & 5 Bd.
1/25/2011
79
T L
APPENDIX 2
8.4. Precision Linear Control Panel Internal Wiring Bottom Half vers. 4 & 5 Bd.
Figure 104. Precision Linear Control Panel Internal Wiring Bottom Half vers 4 & 5 Bd.
80
1/25/2011
T L
APPENDIX 2
8.5. Power & Safety Conns. Wiring
Figure 105. Power & Safety Conns. Wiring.
1/25/2011
81
T L
APPENDIX 2
8.6. Tractor Hydraulic Manifold Panel Wiring (May 2010 -
Figure 105.1 Tractor Hydraulic Manifold Panel Wiring (May 2010 -
82
).
1/25/2011
T L
APPENDIX 2
8.7. Above Ground Guidance Tractor Panel Wiring (Jan. 2008 April 2010)
EA52104 Panel
Figure 106. Above Ground Tractor Panel Wiring (Jan. 2008 April 2010).
1/25/2011
83
T L
APPENDIX 2
8.8. Above Ground Guidance Tractor Panel Wiring (May 2010 -
EA52304 Panel (12VDC Safety Relay added Jan. 20, 2011)
Figure 106.1. Above Ground Tractor Panel Wiring (May 2010 -
84
).
1/25/2011
T L
APPENDIX 2
8.9. PLC Panel to Above Ground Tractor Guidance Panel Wiring
Figure 107. PLC Panel to Above Ground Tractor Guidance Panel Wiring.
1/25/2011
85
T L
APPENDIX 2
8.10. Buried Wire Guidance Tractor Panel Wiring (Jan. 2008 April 2010)
EA52109 Panel
Figure 108. Buried Wire Tractor Panel Wiring (Jan. 2008 April 2010).
86
1/25/2011
T L
APPENDIX 2
8.11. Buried Wire Guidance Tractor Panel Wiring (May 2010 -
EA52309 Panel
Figure 108.1 Buried Wire Tractor Panel Wiring (May 2010 -
1/25/2011
).
87
T L
APPENDIX 2
8.12. PLC Panel to Buried Wire Tractor Guidance Panel Wiring
Figure 109. PLC Panel to Buried Wire Guidance Panel Wiring.
88
1/25/2011
T L
APPENDIX 2
8.13. Straddle Ditch Guidance Tractor Panel Wiring (Jan. 2008 April 2010)
Figure 110. Straddle Ditch Tractor Panel Wiring (Jan. 2008 April 2010).
1/25/2011
89
T L
APPENDIX 2
8.14. Straddle Ditch Guidance Tractor Panel Wiring (May 2010 -
EA52304 Panel (12VDC Safety Relay added Jan. 20, 2011)
Figure 110.1 Straddle Ditch Tractor Panel Wiring (May 2010 -
90
).
1/25/2011
T L
APPENDIX 2
8.15. PLC Panel to Straddle Ditch Tractor Guidance Panel Wiring
Figure 111. PLC Panel to Straddle Ditch Guidance Panel Wiring.
1/25/2011
91
APPENDIX 2
T L
8.16. PLC Panel 20/15 Swivel Cable Wiring
Figure 112. PLC Panel 20/15 Swivel Cable Wiring.
8.17. Water Pressure Sensor Wiring
Figure 113. Water Pressure Sensor Wiring.

92
1/25/2011
T L
APPENDIX 2
8.18. Collector Ring Wiring
Figure 114. Collector Ring Wiring.
1/25/2011
93
APPENDIX 2
T L
8.19. Right End Tower Wiring
Figure 115. Right End Tower Wiring.
94
1/25/2011
T L
APPENDIX 3
9. APPENDIX 3: Service Parts

EA51056
EA52512
EC50351
EC98379
EC98389
EH53127
EW53121
EW53122
EW53123
EW53124
EW53125
EW53126
EC50761
EC50762
EC5096
EC5094
EC50951
EC5322
EH53240
EH56613
ES53218
ES53219
FW56512
FW56513
HF57731
HF57778
HV98064
HV98065
HV98382
HV98383
HV98384
HV98392
HV98386
MD89820
ES532180
DC-DC Converter, Engine 12 to 24 VDC 160 Watt (5.5 amp max output)
End Tower Reversing Switch Assy with Cable
Precision Linear Control - Circuit Board Only
Sterling Coil 12 VDC with wire leads (black coil CCS012L)
Sterling Coil 24 VDC with Deutsche Connector and wire leads (black coil CCS024H)
Precision Linear Control Face Plate, Keypad, Circuit Board, & Screen, Version 5
Precision Linear Control Power Wiring Harness
Precision Linear Control Above Ground Steering Wiring Harness
Precision Linear Control Communication Wiring Harness
Precision Linear Control Analog Wiring Harness
Precision Linear Control Right/Left Wiring Harness
Precision Linear Control Safety Wiring Harness
Fuse 20 amp AGC
Fuse 10 amp AGC
Fuse 5 amp AGC
Fuse 3 amp AGC
Fuse MDL amp slow acting
BEI Serial Encoder
Point Manifold PCB (6/04 - )
Weather Guard Protective Rubberized Spray
Speed Sensor M12
Sensor Cable (Black)
Star Washer 1/4
Star Washer 5/16
Replacement Element for Motor Port Filters in Manifold Body (2/09 - )
Replacement Element for Pressure in Manifold Body - 90-Micron
Motorized Flow Control Valve for Speed Control in Manifold 3 GPM
Motorized Flow Control Valve for Speed Control in Manifold 5 GPM
Cartridge Valve 2-Way for Booster Control Valve
Cartridge Valve 3-way for End Gun Shutoff
Cartridge Valve 4-Way for Direction Control - Silver Plated (1/08 - )
Magnet for Solenoids
Body with Ports for 2-Way Booster Control Valve
Digital Multimeter - Omega
Sensor Tester
Above Ground Guidance

EH50734
Linear Logic Bd II for Above Gnd Cable Gd
EH52124
Relay 24 VDC, Automotive style
ES52560
Mercury Tilt Switch for Secondary Safety
ES53192
Proximity Switch Above Ground Cable Guidance
Buried Wire Guidance
EA52253
Dummy Load For Bur Wire
EC50661
Osc PCB II
EC50665
Osc Mother PCB (use in old style, screw on lid type enclosure for Oscillator)
EC50681
Guid Cntrl PCB II
EC50687
Multi-Mother Bd (use in new plastic enclosure for both Guidance and Oscillator Boards)
ED50704
Antenna 1000 HZ for Buried Wire Guidance, 25 ft. Leads
ED5079
Antenna 1200 HZ for Buried Wire Guidance, 25 ft. Leads
EH53908
Heat Shrink Tubing 1/2 X 6 (Buried Wire Splice)
1/25/2011
95
APPENDIX 4
T L
10. APPENDIX 4: Set-Up Records
DATE/TIMES
Item
Screen 1
Screen 2
Screen 3
Setting
N/A
N/A
______
Choices/Units
Display current date & time, Hr:Min:Sec
Display the Run Times
Enter date (mm/dd/yy), day, time and AM or PM
SYSTEM SETUP (defaults)

Item
Units
Irrigated Width
Water Supply
Water Flow
Left (Tractor) Gear
Left (Tractor) Tire
Right Gear
Right Tire
Max Speed
Min Appl.
Spd Adj Rate Left
Spd Adj Rate Right
Analog Water Pressure
Full Scale
Low Water Press
Initial Delay
Water Flow Meter
Gal/Pulse
Linear Type
Example
English
1285
Hose
800
68:1
23.5
68:1
23.5
60
.20
.018
.018
Yes
100
12
00:30
15:00
Yes
1.25
ULTRA
Setting
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
Choices/Units
English or Metric
Ft
GPM
IPM
in.
sec/IPM
sec /IPM
Yes/No
0 to 200 (Max Pressure on 4 to 20 mA sensor)
psi
mm:ss
mm:ss
Yes/No
EG AREAS
EG AREAS
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
96
Enable/Disable
Setting
RT EG Area 1
_______deg To _______deg
RT EG Area 2
_______deg To _______deg
1/25/2011
T L
APPENDIX 4
AUX APPL
AUX APPL
Item
Enable/Disable
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
Guidance Type
BEI Encoder
Steering Sig Time
4
Stay Steering Time
12
Set BEI Angle to 0
Press Enter at 0
2:1 Steering Angle
0.5
3:1 Steering Angle
1.0
Primary Safety Level
6.0
Anti Ovrstr Out
1.0
Anti Ovrstr In
1.0
Anti Ovrstr Back Out
1.0
Setting
BEI
______
______
______
Choices/Units
Above Cable SRH280 or Buried Wire
sec
sec
Yes/No (Set to 0 degrees at startup)
______
______
______
______
______
______
deg
deg
deg
deg
deg
deg
Setting
______
______
______
______
______
______
______
______
______
______
______
______
______
Choices/Units
ft
ft
min.
FWD, REV, Both, NEITHER
Yes/No,
ft
Yes/No
Enable/Disable
Linear/Pivot
0 or 180
Left or Right
Enable/Disable
Yes/No
RUN SETUP
Item
AR/AS Setpoint FWD
AR/AS Setpoing REV
AR/AS Delay Timer
Ditch Feed Auto Reverse (if Ditch)
Re-Set Distance
Enter Distance
Operating Mode
Span Position (Linear Mode)
End to use for Distance Counter
Low Power Safety
Rotate Tractor 90 Degrees
1/25/2011
97
T L
98
NOTES
1/25/2011
T L
1/25/2011
NOTES
99

ULTRA Linear Operators Manual

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

ULTRA Linear Operators Manual

Transféré par

Droits d'auteur :

Formats disponibles

Irrigation Company

ULTRA Linear System

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

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

CONTROL PANEL ................................................................................................................................... 11

Control Panel Overview ................................................................................................................................... 11

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

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

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

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

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

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

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

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

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

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

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

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

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

INITIAL START-UP OF SYSTEM ............................................................................................................ 23

Setup of Control Panel .................................................................................................................................... 23

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

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

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

OPERATION OF SYSTEM ....................................................................................................................... 28