Topcom X20 User Manual

V1.98 21/06/06

X20/X15/X10 Operators Manual

Spray Rate Control

A2677 V1.98 1.4

W133

V1.98 21/06/06V1.98 21/06/06

Page 2

As with any computer operated equipment, software and/or hardware is in many cases changed and upgraded over the life of the equipment. KEE Technologies software engineers are constantly working on software enhancements which will provide you with many additional benefits and features in the future.

The ZYNX System will keep on evolving! ...to ultimately improve your ‘bottom line’! KEE Technologies personnel have records of all changes implemented to your system with the subsequent serial

number.

To keep this Operator’s manual “alive” and current with your equipment and software versions you will need to administer and document the evolution of your ZYNX System in this manual.

In some cases we will provide you with software upgrades and additional/ replacement pages to add to this manual. With major software upgrades we may provide you with a completely new manual for the corresponding ZYNX Solution.

When talking to KEE Support staff, always have this manual with you, as we may ask you what version manual you are currently looking at to ensure we all talk the same language. For this purpose all pages are coded as follows.

Page number Date when written Software version

Below is space provided to keep records of any software and hardware upgrades you may have received.

Type of upgrade (software or hardware) Version Date Manual upgraded

09/06 09/06

V1.98 V1.98

21/06/06 21/06/06

ZYNX X20 Sprayer Software (ex factory) ZYNX X15 Sprayer Software (ex factory)

B C

Contents

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V 1.86

IINNSSTTAALLLLAATTIIOONN

1.0

FFoorr AALLLL IInnssttaallllaattiioonnss aanndd SSeerrvviicciinngg ooff SSpprraayy EECCUU’’ss 1100

1.1 Installing the Spray ECU (All Models) 11

1.2 Installing Spray ECU 30S KEE Spray Controller Kits 13

1.2.1 Installing the Tractor Harness 13

1.2.2 Installing the Sprayer Harness 16

1.2.3 Installing the Valve Harness 20

1.3 Installing Spray ECU 30S kits to Existing KEE Controllers 25

1.4 Installing to Existing Raven Controllers 27

1.5 Connecting the Spray ECU to the Battery 30

SPRAYER SETUP OPTIONS

4.0 GPS 46

5.0 ECU 48

5.1 ECU (Spray ECU ONLY) 50

6.0 TANKS 52

6.1 REGULATOR VALVE SETTINGS 54

6.2 PROPORTIONAL VALVE SETTINGS 56

7.0 SECTIONS 58

8.0 SWITCHES 60

8.1 SWITCHES (SPRAY ECU 2 ONLY) 62

8.2 CUSTOM SECTION MAPPING 63

9.0 SENSORS 64

9.1 SENSORS (SPRAY ECU 2 ONLY) 66

10.0 SETUP 67

10.1 SETUP (SPRAY ECU2 ONLY) 69

10.2 WHEEL CALIBRATION 70

11.0 UNITS 71

12.0 ALARMS 72

12.1 ALARM DEFAULTS 74

13.0 PRESETS 75

14.0 SIMULATION 76

15.0 Other 77

16.0 SAVING THE SPRAYER CONFIGURATIONS 78

16.1 CHANGE SETTINGS TO THE CURRENT CONFIGURATION 79

Content Page No. IInnttrroodduuccttiioonn 66

HHooww ttoo UU

ssee tthhiiss MMaannuuaall 77

GGEETTTTIINNGG SSTTAARRTTEEDD 3311

2.1 Starting the X15 Console 32

2.2 Starting the X20 Console 33

2.3 Registration and Sprayrate Control Software Version 34

2.4 Overview of Functions-

WWoorrkkiinngg SSccrreeeenn

2.5 Navigating Around the OPTIONS window 38

3.0 Configuration Setup 42

3.1 Adjust Audio Volume 42

3.2 Configuration 42

3.3 Factory Configuration 43

3.4 Quick Setup (For Factory Configurations) 44

3.5 Select the ‘Change/View Configuration’ button 44

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Contents

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V 1.86

17.1 Pressure Window 82

17.2 Calibrating the Pressure Sensor 83

17.3 Manual Entry of Pressure Calibration Factors (Spray ECU) 83

17.4 Flow Window 84

17.5 Speed Window 85

17.6 Area/Volume Window 86

17.7 Tank Setup 88

17.7.1 Fill The Tank 89

17.8 Calibrate The Flow Meter 90

17.8.1 Flow Calibration for Normal Valves 90

17.8.2 Flow Calibration for Balanced Valves 91

17.9 Enable Lockout Feature 92

17.9.1 Enable Lockout 92

17.9.2 Dis-able Lockout 92

17.10 Sprayer Switchbox 93

START SPRAYING

18.1 Simulate Spraying 95

18.2 Start Spraying 96

18.3 Using ZYNX Guidance with the Spray Controller 97

TESTING

19.1 Regulator Valve 100

19.2 ZYNX Switched Power 100

19.3 Dump Valve 101

19.4 KEE Sensors 101

19.5 ‘3 Wire Section Valves’ 102

19.6 PWM Regulator Valve 102

SYSTEM COMPONENTS AND SPECIFICATIONS

20.1 Sprayer Components- Part List 103

20.2 Specifications 104

20.2.1 ZYNX Console 104

20.2.2 KEE Sensors (Ground, Fan and Auxiliary Sensors) 104

20.2.3 Flow Sensors 104

20.2.4 Pressure Sensor 105

Content Page No. SSEETTTTIINNGG UUPP TTHHEE SSPPRRAAYYEERR

WIRING CONNECTION TABLES

21.1 Selecting the Right Controller 107

21.2 Wiring Connection Tables for Spray ECU Controllers 109

21.3 Spray ECU (with tails) 111

21.3.1 A1999 (Hagie) Connection Tables 112

21.3.2 A2006 (Raven) Connection Tables 114

21.4 Spray ECU 116

21.4.1 A2036 Spray ECU Connection Tables (060001-060014) 117

21.4.2 A2036 Spray ECU Connection Tables (060015- 060053) 120

21.5 Spray ECU (Raven) 123

21.5.1 A2445 KEE Spray ECU 3 Connection Tables (()50001- 050011) 124

21.5.2 A2445 KEE Spray ECU 3 Connection Tables (060001 -060037) 128

21.6 Spray 10SR 132

21.6.1 Spray ECU 10SR Wiring Connection Tables (060000-060040) 133

21.6.2 Spray ECU 10SR Wiring Connection Tables (060041- ) 137

21.7 Spray ECU 30S 141

21.7.1 Spray ECU 30S Wiring Connection Tables 142

21.8 Hardi 5500 Spray ECU 145

21.8.1 Hardi 5500 Spray ECU Connection Tables 146

21.9 KEE Sprayrate Interface 148

21.9.1 KEE Sprayrate Interface Wiring Connection Tables 149

WIRING SCHEMATICS OF KEE SPRAY ECU TRACTOR AND SPRAYER LOOMS 151-164

SERVICE BULLETINS

23.0 Pressure Relief Valve installation to Raven Fast Flow Valves 166

Contents

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Major Topic Heading

Introduction

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Introduction

The Spray ECU is a new generation spray controller to used in conjunction with the NEW X20 or ZYNX X15 consoles brought to you by KEE Technologies. The Console is the graphical interface of the Spray ECU controller. The Spray ECU replaces the KEE Sprayrate Interface.

The Spray ECU can control up to 30 section valves (3 wire) and allows Automatic Section Control (ASC) of the 30 section valves (the X15 Console can control up 15 sections under ASC). The Spray ECU can control up 2 liquid tanks directly. If the Spray ECU is used in conjunction with a Multi-Drive Electronic Control (MDECU) unit, it can control up to 3 liquid injection tanks.

The Spray ECU can handle ‘Boom Sensing’ inputs therefore can be connected to existing Remote switches. The Spray ECU also has a new feature called ‘Section Mapping’ which allows one section switch to control a number of section valves. Therefore the existing KEE Switchbox or Remote switches (usually 6 or 8 switches) can control all 30 section valves when they are controlled manually. The ZYNX sprayer software sets up the section mapping automatically. The ASC still controls all 30 section valves individually.

The Spray ECU can control Regulator or Proportional type control valves. The Spray ECU can control ‘3 Wire’, ‘2 Wire’ (reverse polarity) or solenoid type section valves.

How to use this Manual

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HOW TO USE THIS MANUAL

All operators who have a Spray ECU installed must read the following page: Section 1.0 ‘For all Installations and Servicing of Spray ECU’s’.

UUppggrraaddiinngg tthhee ZZYYNNXX SSpprraayy RRaattee CCoonnttrrooll SSooffttwwaarree If the ‘Spray Rate Interface’ or ‘Spray ECU’ is already installed and you are using this book to upgrade the ZYNX Sprayrate Control software to a later version, then go to straight to Section

3.0 ‘Configuration Setup’.

IInnssttaallllaattiioonn ooff tthhee SSpprraayy EECCUU

1. Read Section 1.0 ‘For all Installations and Servicing of Spray ECU’s’ before attempting

any installations

2. Section 1.1 has details about installing the Spray ECU controller, Power/Comms harness

and KEE Sprayer Switchbox.

3. Then select one of the following installations, depending on which Spray ECU kit

was purchased:

3a. Section 1.2: Installing a complete KEE Spray ECU 30S kit. This section explains how to

install the following: Tractor harness, Sprayer Harness, Valve Harness, wheel sensor kit, flow sensor kit, connect to a regulating valve, electronic pressure sensor and connect to a dump valve.

3b. Section 1.3: Installing a Spray ECU 30S kit to an existing KEE MK5 Spray controller or

KEE Spray Rate Interface.

3c. Section 1.4: Installing the 10SR Spray ECU to existing Raven 4xx, 6xx, 4400 and 4600

series controllers. The Spray ECU 10SR has been pinned to allow direct replacement of some of the Raven 4xx, 6xx, 4400 and 4600 series controllers.

4. This section connects the Spray ECU to the battery. The hardware installation is

complete.

5. Once the Installation is complete then go to Section 2.0 ‘Getting Started’. Go to Section

2.1 if starting an X15 Console

OORR

to Section 2.2 if starting starting an X20 Console. These sections explain starting the ZYNX Console. The manual from Section 2.3 onward will be the same whether an X15/X10 Console or X20 Console is used. Section 2.3 checks the spraying software is registered. This section gives an overview of the Sprayer Working Screen and how to ‘Navigate Around the Screen’ during setting up the sprayer software.

6. Section 3.0: ‘Configuration Setup’ explains how to load your KEE Spray kit or Sprayer from the factory configurations files loaded on the ZYNX Console, if your sprayer is listed. These configuration files contain most of the sprayer settings required to set up your sprayer. If your sprayer is listed in the Factory Configurations then you can choose to do the Quick Setup (Section 3.4)

OORR

manually follow the manual through all the

sprayer software setup options (Section 4 to 15) in the Software Setup Section.

7. (Section 4 through to 15): The Sprayer Software Setup section takes the operator through the 11 pages of the OPTIONS window to setup the sprayer.

How to use this Manual

8. Section 16: ‘Saving the Configurations’ section shows the operator how to save and name the sprayer settings entered into the Sprayer Software Setup (Sections 4 to 15).

9. Section 17:’Setting up the Sprayer’ explains the Pressure, Flow, Speed, and Area/Volume windows. This section explains how to ‘Fill the Tank’ and the Sprayer Switchbox. This section also explains how to Calibrate the Pressure Sensor and Flow sensor. Setting up is now complete the sprayer is ready for testing.

10. Section 18: ‘Start Spraying’ section explains how to test and simulate spraying using water before any actual spraying takes place. The section then explains how to start spraying, in either MANUAL or AUTOMATIC mode.

11. Section 19: The ‘Testing’ section explains how to test the Regulator Valve, test for Switch power for the Spray ECU, test the dump valve, test KEE sensors, test for 3 wire section valves and test PWM valves.

12. Section 21: The ‘Wiring Connection Tables’ section shows how to select between ‘Spray Rate Interface’ and ‘Spray ECU’ controllers when selecting in the software. This section also contains the Wiring Connection tables for each of the connectors for the different Spray ECU’s.

13. Section 22: This section contains the schematic wiring diagrams of the current the KEE Spray ECU 30S Tractor and Sprayer harness’s available.

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Spray Rate Control

Installation

Warning when Installing Spray ECU Controller

1.0 FOR ALL INSTALLATIONS AND SERVICING OF SPRAY ECU'S

Damage will occur if any external power is applied to the Section Drive Outputs on the Sprayer ECU. Follow this procedure to ensure that damage is avoided.

Disconnect both the ZYNX Console and Spray ECU controller from the battery before charging, jump starting or welding on the vehicle and/or sprayer.

TTeessttiinngg PPrroocceedduurree:: Commence test by disconnecting the existing tractor harness from the existing controller. AA.. IInnssttaallllaattiioonnss wwiitthh nnoo eexxiissttiinngg sswwiittcchhbbooxx ((SSwwiittcchheess oonn EExxiissttiinngg CCoonnttrroolllleerr)):: With ignition key on, check each Section Drive Output pin on the existing tractor harness for

voltage (refer manufacturer of existing tractor harness for pin detail). Locate where voltage is supplied to determine if it can be removed without limiting existing functionality. If it is not possible to remove this voltage then you must install a Section Drive Output Protection Adaptor. (A2812 for 37-pin on Connector 1 and A2813 for 16-pin on Connector 3) If no voltage is found disconnect the vehicle's battery and continue with installation.

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Determine if it is possible to disconnect the existing switchbox without limiting existing functionality (e.g. Boom Lift, Lower or Fold). If so, disconnect the switchbox, switch the ignition key on and check each Section Drive Output pin on the existing tractor harness for voltage (refer manufacturer of existing tractor harness for pin detail). If it is not possible to remove this voltage then you must install a Section Drive Output Protection Adaptor. (A2812 for 37-pin on Connector 1 and A2813 for 16-pin on Connector 3)

If no voltage is found disconnect the vehicle battery and continue with installation. Disconnect the vehicle battery before proceeding with any installation or servicing of the Spray ECU, Tractor, Sprayer or Valve Looms.

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Figure 1: Connecting the

Spray ECU to existing Installations.

Installing the Spray ECU

1.1 INSTALLING THE SPRAY ECU (ALL MODELS)

Step 1: Installing the Spray ECU 30S

1. Mount the Spray ECU (Electronic Control Unit) shown in Figure 2 in a suitable position inside the cab ensuring that it and its connectors cannot be accidentally damaged by moving objects, the Spray ECU can be mounted in any orientation. Figure 4 shows the in-cabin assembly showing Spray ECU, Switch Box, Power Comms and Tractor Harness. Please refer to the ZYNX Console (X15 or X20) manual for mounting the ZYNX Console.

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2. Install the Power/Comms Harness. Route the red and black wires to a 12 volt battery.

DO NOT CONNECT TO BATTERY, UNTIL INSTALLATION IS COMPLETE.

Use the cable ties provided to secure the Power/Comms Harness away from hot and moving parts and to avoid chaffing and wear.

3. Plug the ‘Switched Power’ connector that is located on the Power/Comms Harness, into the ‘Switched Power’ connector on the ZYNX Power Cable. If this connection is already utilized, connect it via the A1953 Power Splitter Harness. This connection ensures that the Spray ECU is only powered up when the ZYNX Console is switched ON.

4. One end of the Power/Comms Harness has 'DB 9-Pin' Comms Cable connection. Connect this cable to the next available COM Port at the back of the ZYNX Console.

5. Connect the other end of the Power/Comms Harness to the 16-pin connector marked ‘POWER/COMMS’ on the Spray ECU.

Figure 2: Spray ECU 30S

Figure 3: Sprayer Switchbox

Installing the Spray ECU

6. Connect the Sprayer Switchbox, shown in Figure 3, to the '9-pin connector marked SWITCHBOX on the Spray ECU. Then mount the Sprayer Switchbox using the doublesided tape supplied or other suitable means. Mount the Sprayer Switchbox in a position which is easily accessible while spraying.

Note: The Sprayer Switchbox can be used so, one switch, switches one boom section ON and OFF. If the sprayer has more than six boom sections then the ZYNX Sprayer software can be setup so that one section switch, switches more than one boom section ON and OFF. The operator can custom map the boom sections. See Section 17.10 for details of the functions of the Sprayer switchbox.

7. For reference or troubleshooting at the back of this manual Section 21.7 shows the pin out tables for each of the Spray ECU 30S Connector’s.

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Installation of Spray ECU 30S KEE Sprayer Kits

11..22 IInnssttaallllaattiioonn ooff SSpprraayy EECCUU 3300SS KKEEEE SSpprraayyeerr KKiittss

All KEE Sprayer kits come with their installation guide which is specific to each kit, please use the specific installation guide which come with your KEE Sprayer kit. This section is a general guide for an installation of all KEE Spray ECU 30S Sprayer kits.

This installation guide will take the installer through the following steps:

1.2.1 Installing the Tractor Harness

1.2.2 Installing the Sprayer Harness

1.2.3 Installing the Valve Harness

1.2.1 Installing the Tractor Harness

1. Connect the Tractor Harness to the 37-Pin connector marked CONNECTOR 1, on the Spray ECU. Figure 4 shows the in-cabin assembly showing Spray ECU, Power/Comms Harness, Switchbox and Tractor Harness.

2. Run the Tractor Harness from the Spray ECU to the drawbar or the back of the vehicle. Ensure that the Tractor Harness is tied away from moving, hot or sharp objects. Do not cut or splice the Tractor Harness, all excess cable should be strapped away to avoid vibration and wear.

3. If the Tractor Harness has ‘2’ 37 pin connectors, then connect the ‘37’ pin connector (male pins) marked ‘CONNECTOR 1’ to the plug marked ‘CONNECTOR 1’ on the Spray ECU. Then connect the ‘37’ pin connector (female pins) marked ‘CONNECTOR 2’ to the plug marked ‘CONNECTOR 2’ on the Spray ECU. Note: As a general rule the ‘CONNECTOR 2’ plug is only required if:

a) The sprayer has more than 10 boom sections. b) The sprayer has more than ‘2’ tanks. c) The Spray ECU is connecting to external switches which control the boom

sections (boom sensing); for example boom section switches on a ‘T Bar’ or ‘Joy Stick’ or other ‘third party’ section switches.

4. Normally ‘CONNECTOR 3’ (16 pin) is only required if the sprayer requires extra pressure inputs, tank level sensors and extra encoder inputs. See Wiring Connections table for the Spray ECU 30S (A2643) controller for wiring pin-outs;( See Section 21.7).

5. The Tractor Harness has a 3-pin Weather Pack connector labeled Ground Speed, either an A328 Shaft/Speed Sensor Kit or A449 Radar Sensor Interface Harness (not included in this kit) can be connected to this connector. Typically the Radar Sensor Interface Harness would be connected to the Tractor Harness Ground Speed connector. Only one (1) speed connector must be used at any one time. Refer to 1.2.2 for installing the Shaft/Speed Sensor Kit or Radar Sensor Interface Harness.

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General System Layout for Spray ECU 30S KEE Controller Kits

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Connects to Sprayer Harness

Figure 4: General Incab assembly

General System Layout for Spray ECU 30S KEE Controller Kits

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Tractor Harness

Dump Valve

Sprayer Loom

Figure 5: General Sprayer and Valve harness assembly

Installation of Spray ECU 30S KEE Sprayer Kits

1.2.2 Installing the Sprayer Harness

1. The Sprayer Harness connects to the Tractor Harness at the back of the tractor or vehicle via the connector and continues across the sprayer's chassis to the valve set. Figure 5 shows the Sprayer Harness and Valve Harness Assembly.

2. Do not cut or splice the Sprayer Harness. Excess cable should be strapped away to avoid vibration and wear.The typical Sprayer Harness has 5 connectors, they are labeled as follows:

GGrroouunndd SSppeeeedd

- connects to the Shaft/Speed Sensor Kit which is supplied as part of this kit.

FFllooww MMeetteerr 11

- connects to a flow meter (not supplied).

PPrreessssuurree SSeennssoorr 11-

connects to the Pressure Sensor which is supplied as part of this kit.

RREEGG VVaallvvee 11-

connects to a regulator valve (not supplied).

VVaallvvee HHaarrnneessss-

connects to the Valve Harness which is supplied as part of this kit.

Note: The Sprayer Harness may have other connectors, refer to the Sprayer Installation kit that came with your sprayer kit for more information. The Dump Valve connector may be located on the Sprayer Harness. If the Valve Harness has an ‘Arag Interface box’ incorporated into the Valve Harness, then the ‘Dump Valve’ connector will be located on the Valve Harness.

Troubleshooting Tip: For testing purposes on all 3-pin sensor connectors (Shaft/Speed Sensor and Flow Meter) the voltage on each pin should be as follows: Pin A: +5 VDC Signal, Pin B: Ground, Pin C: +12VDC Sensor Power. Refer to Figure 6 below:

Connecting to a Speed Sensor

This installation is used if connecting an A328 Shaft/Speed Sensor Kit (for ground speed) or A449 Radar Sensor Interface Harness (not supplied) to the Ground Speed connector on either the Tractor Harness or Sprayer Harness. CCoonnnneecctt ttoo oonnllyy oonnee ((11)) ooff tthhee GGrroouunndd SSppeeeedd ccoonnnneeccttoorrss..

Select one of the following:

a) Installing the Shaft/Speed Sensor Kit to an un-driven wheel on either the Tractor

Harness or Sprayer Harness;

b) Installing the Shaft/Speed Sensor Kit to the Tail Shaft of a vehicle on either the Tractor

Harness or Sprayer Harness;

c) Use and existing radar speed sensor for ground speed.

Installation of the Shaft/Speed Sensor kit to an un-ddriven wheel for Ground Speed

1. The Shaft/Speed Sensor and Wheel Stud Magnets can be fitted to any un-driven ground wheel, for example: front wheel of tractor or wheel on trailing sprayer. The magnet activates the sensor as the wheel magnets sweep past. Refer to Figure 8.

Note: Use of a driven wheel for ground speed may be subject to "wheel slip" and may not always reflect true ground speed.

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Figure 6 : 3-Pin Weather Pack Sensor

Installation of Spray ECU 30S KEE Sprayer Kits

2. Glue the magnets to the wheel studs with the side marked with a cross (+) facing the Shaft/Speed Sensor. Use any silicone or epoxy type adhesive allowing adequate time to set. Ensure that the magnets are spaced equally around the wheel to ensure accurate speed update. To ensure adequate speed update place magnets onto ALL of the available wheel studs. A Wheel Calibration Factor of no greater than 0.6m (24 inches) is required. Please note that the Hose Clamp and Magnetic Block are not used in this case.

3. The Shaft/Speed Sensor must be rigidly mounted to an existing structure on the axle, ideally in a protected position to face the magnet. The Mounting Bracket Assemblies (slotted brackets and angle brackets with hose clamps) provided can be used to construct a mounting bracket refer Figure 7 or you may fabricate your own mounting bracket to suit the sprayer chassis. IImmppoorrttaanntt:: TThheerree mmuusstt bbee NNOO mmoovveemmeenntt ooff tthhee sseennssoorr rreellaattiivvee ttoo tthhee mmaaggnne

ett..

4. The Shaft/Speed Sensor to Wheel Stud Magnet distance needs to be 2 to 3 mm (1/16 to 1/8 inch). The Shaft/Speed Sensor must be mounted so that the Wheel Stud Magnets pass the sensor evenly and squarely.

5. Protect the Shaft/Speed Sensor and wiring from damage if necessary by welding or bolting a suitable plate over the. Damage to the front face of the Shaft/Speed Sensor will stop the speed readout and prevent the controller from working.

6. If the Shaft/Speed Sensor is mounted on a steered wheel, then make sure the sensor moves with the steering mechanism, to maintain constant clearance between the magnets and the sensor when the wheel is turning from lock to lock.

7. Use the 3-pin Weather Pack Extension provided if required, connecting the Shaft/Speed Sensor to either the Ground Speed connector on the Tractor Harness or Sprayer Harness.

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Figure 7 : Shaft/Sensor with Mounting Bracket

Figure 8 : Shaft/Speed Sensor on an

un-driven wheel installation

Installation of Spray ECU 30S KEE Sprayer Kits

Installation of a Shaft/Speed Sensor kit to a tail shaft

1. On a tray mounted sprayer the Shaft/Speed Sensor Kit can used to read from the vehicle tail-shaft. Refer to Figure 9. Using the Hose Clamp or other suitable means securely mount the Magnet Block on the flange between the transmission housing and the tail shaft. Note: Do not attach the Magnet Block directly to the tail shaft as its position changes through its rotation. The Wheel Stud Magnets are not used in this case.

2. Using an existing bolt on the transmission housing and the supplied Mounting Brackets or other suitable means, securely mount the Shaft/Speed Sensor so it squarely faces the Magnet Block with a clearance of 2 to 3mm (1/16 to 1/8 inch).

3. Ensure that the Shaft/Speed Sensor is firmly attached and protected so that it cannot be damaged by wire or stones. If necessary cover the Shaft/Speed Sensor with a plate.

4. Use the 3-pin Weather Pack Extension provided if required, connecting the Shaft/Speed Sensor to the Ground Speed connector on the Tractor Harness or Sprayer Harness.

Using an existing radar speed sensor for ground speed

1. An optional Radar Sensor Interface Harness (A449 - not provided as part of this kit but may be ordered separately) allows direct connection to any existing radar speed sensor on the tractor.

2. Connect the Radar Sensor Interface Harness to the Ground Speed connector on the Sprayer Harness or Tractor Harness then connect this wire to the signal wire from the radar sensor (not provided) to enable the Spray ECU to read the speed. Note: Check the radar sensor manufacturer's manual before attempting connection. Use the Extension Harness provided if required connecting the radar sensor to the Ground Speed connector on either the Sprayer Harness or Tractor Harness.

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Figure 9 : Shaft/Sensor Sensor installation a tail shaft

Installation of Spray ECU 30S KEE Sprayer Kits

Connecting to Flow Meter

1. The flow meter (not supplied) is installed between the regulator valve and the section valves. The flow meter will be installed so that it measures ONLY the quantity of liquid being delivered to the spray line.

Note: There must be no return line to tank or pump after the flow meter.

2. Connect the flow meter 3-pin connector to the 3-pin connector marked Flow Meter 1 on the Sprayer Harness.

Note: The flow meter may require a connector change to attach to the 3-pin connector marked Flow Meter 1 on the Sprayer Harness. Refer to the flow meter manufacturer's specifications for correct pin allocation. Care should be taken when replacing these connectors not to damage the Sprayer Harness or flow meter and connectors should be fully circuit tested prior to installation.

3. Most flow meters have a label on the meter body that shows the flow meter Calibration Factor in pulses/volume. For example: '645 ppl' (pulses per litre) or 2441 ppg (pulses per gallon). This value is the Calibration Factor and will be required to be entered into the sprayer software setup. This means the flow meter sends 645 pulses to the Spray ECU for every litre (or 2441 pulses for every gallon) of liquid that passes through the flow meter.

4. For connection to a Raven flow meter: The value marked on the label represents pulses/10 units of liquid. Divide this number by 10 for the correct value to enter as the Calibration Factor into the Sprayer Software Setup.

Connecting to the Regulator Valve

1. The regulator valve (not supplied) is a motorized flow control valve used to maintain the product flow to the section valves. It will be situated between the pump and the flow meter.

2. All bypass or agitation return lines that return to tank must be taken before the regulating valve, so there is no return path after the regulating valve and the flow sensor.

3. Using the Regulator Valve Adaptor Harness (A802) connect the regulator valve's 2-pin connector to the 2-pin connector marked REG Valve 1 on the Sprayer Harness.

Note: The regulator valve may require a connector change to attach to the 2-pin connector marked REG Valve 1 on the Sprayer Harness. Refer to the regulator valve manufacturer's specifications for correct pin allocation. Care should be taken when replacing these connectors not to damage the Sprayer Harness or regulator valve and connectors should be fully circuit tested prior to installation.

4. When you test the sprayer with water you may find that the regulator valve works in the opposite direction than is required. For example the pressure increases when it should decrease. You can set the "Reverse Valve Direction" in the Sprayer Setup software to remedy this.

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Installation of Spray ECU 30S KEE Sprayer Kits

Pressure Sensor installation and connection

1. Mount the Pressure Sensor (A092) either upright or horizontal and support the brass gauge saver. To properly measure Spray Line operating pressure the Pressure Sensor must be positioned between the flow meter and the section valves. The supplied Pressure Sensor is a 5 Bar (72 psi) pressure sensor.

2. Connect the Pressure Adaptor Harness (H1125) to the connector labeled Pressure Sensor 1 on the Sprayer Harness.

3. Undo the two (2) nuts on top of the Pressure Sensor.

4. Place the two ring terminals on the Pressure Adaptor Harness onto the terminals on the Pressure Sensor. It doesn't matter which way around the terminals are attached to the Pressure Sensor.

5. Once the ring terminals are placed on the Pressure Sensor terminals replace the two (2) nuts and tighten the nuts securely.

1.2.3 Installing the Valve Harness

1. The Valve Harness continues from the connector on the Sprayer Harness and connects to the Section and Dump Valves on the Sprayer.

2. The Valve Harness normally contains connectors for the section valves; either they are; ‘3 Wire section valves’, ‘2 Wire Section Valves’ or ‘solenoid valves’.

See below for an explanation of the different types of section valves.. Note: If the Valve Harness has an Arag Interface box incorporated into the harness, then the Dump Valve plug will be on the Valve Harness.

5. The typical Valve Harness has the following connectors, they are labeled as follows: DDuummpp 11-

connects to the Dump Valve.

SSeeccttiioonn XX-

connects to the Section Valves. ‘X’ represents the section number.

SSpprraayyeerr HHaarrnneessss-

connects to the Sprayer Harness.

3. There are different Valve Harness depending on which type of section valves on fitted on the sprayer.

Note: If the Valve looms need to be re-terminated because the connectors are different to the section valves being connected to, then make sure the ‘Sprayer Harness’ is disconnected from the ‘Tractor Harness’. Otherwise damage to the Spray ECU

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occur if

the wires are shorted out during the installation.

4. Secure the Valve Harness away from moving, hot or sharp objects to avoid chaffing and wear, using the cable ties provided.

6. Connect the Valve Harness to the Sprayer Harness.

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Installation of Spray ECU 30S KEE Sprayer Kits

Single Line Install

5. Connect the connectors marked Section X (‘X’ represents the section number) to the correct section valves. Section 1 connects to the section valve on the far left. Section 2 connects to the next section valve and so forth until all the section valves are connected to the Valve Harness.The section valve with the highest number will operate the boom section on the far right. If there are too many connectors for the section valves, then as a general rule use the connectors with the lowest numbers first.

6. Cable-tie the spare connectors to the Valve Harness.

Dual Line Install

7. Connect the connectors using the lowest numbers first that operate the primary spray line (Line A). Starting with Section 1 to operate the section on the FAR LEFT of the spray line, when facing forward finishing with the highest number section valve on Line A to operate the FAR RIGHT.

8. Connect the connectors to the section valves which are going to operate the secondary line (Line B). Starting the lowest number on the Line B to operate the FAR LEFT boom section, finishing with the highest number boom section on the Line B to operate the FAR RIGHT boom section.

Note: If the Valve Harness needs the connectors replaced to suit the valves connectors then make sure the Sprayer Harness is disconnected from the Tractor Harness. Otherwise damage to the Spray ECU will occur if the wires are shorted out during this procedure.

Connecting to the Dump Valve

6. The dump valve (not supplied) must be located between the pump and the flow meter.

7. The dump valve is activated when all sections are switched OFF, or the Master Switch is switched OFF, therefore all the flow is diverted back to the tank.

8. Connect the ARAG connector, labeled Dump 1 to the dump valve.

Note: During setting up of the sprayer the wires in the ARAG connector may have to be swapped, if the dump valve is going in the wrong direction.

9. If the Dump Valve connector is on the Sprayer Harness, then an adaptor will be required to connect the 4-Pin Weather Pack to the Dump Valve. Connect the correct adaptor to the Dump Valve from the following adaptors:

a) A2266- if connecting to a 2-wire dump valve and 12v is applied to the dump

valve when the Master switch is OFF.

b) A2267- if connecting to a solenoid valve, with 6mm spade terminals and 12v

is applied to the dump valve when the Master switch is OFF.

c) A2268- if connecting to a 3-wire dump valve and 12v is applied to the dump

valve when the Master is OFF.

d) A2269- if connecting to 3-wire dump valve and 12v is applied to the dump

valve when the Master is ON.

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Installation of Spray ECU 30S KEE Sprayer Kits

9. Once all the ARAG connectors are in place, using a screwdriver tighten the screw at the top of the ARAG connector to secure the connector to the section and dump valves.

10. Tidy any excess harness using cable ties.

11. To complete the installation go to Section 1.5 to connect the Spray ECU Power/Comms harness to the battery.

Explanation of the Different types of Valves

22-wwiirree VVaallvvee ((RReevveerrssee PPoollaarriittyy)) Refers to an electric section, dump or regulator valve. The valve is driven by an electric motor that is able to rotate in both directions. 2 wires are connected to this type of valve from the controller. To rotate the motor 12v is applied to one of the wires whilst GND is applied to the other. When opposite voltage is applied to the two wires the motor will rotate in the opposite direction. Common terms for this system are Reverse Polarity or Bi-Directional.

33-wwiirree VVaallvvee Refers to an electric section, dump or regulator valve. The valve is driven by an electric motor that is able to rotate in both directions. Unlike the 2-wire valve, the 3-wire valve has inbuilt changeover relays that change the motor direction depending on whether 12v or 0v is applied to the signal wire. Constant 12v and GND are required in addition to the signal wire.

SSoolleennooiidd VVaallvvee Refers to electromagnetic coil type valves. They usually consist of a coil that when exposed to voltage produces a magnetic field. The magnetic field draws a needle against a spring away from it’s seat to allow liquid to flow. GND and 12v signal is required for this type of valve.

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Major Topic Heading

Plumbing for Diaphragm Pumps for KEE Sprayer Kits

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Figure 10: Plumbing Diaphragm Pumps for KEE Sprayer kits

Plumbing for Centrifugal Pumps for KEE Sprayer Kits

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Plumbing for Centrifugal Pumps for KEE Sprayer Kits

Figure 11: Plumbing for Centrifical Pumps for KEE Sprayer kits

Installing Spray ECU 30S Kits to Existing KEE Controller

1.3 INSTALLING SPRAY ECU 30S KITS TO AN EXISTING KEE CONTROLLER

Note: Use this install guide if replacing an existing a KEE MK3, KEE MK5 sprayer console or KEE Sprayrate Interface.

1. Before removing the existing Controller Run the Sprayer and record the minimum and maximum pressure and flow rates attainable. Ensure that the system is functioning correctly before removing the controller.

2. Record all of the cal factors and section width values. These can then be easily transferred to the ZYNX after installation. It will also be a useful reference if replacing the existing controller.

3. Remove the existing KEE Spray Controller console or KEE Sprayrate Interface.

4. Remove the existing Tractor harness.

5. Install the Tractor Adaptor harness that came with the Spray ECU kit. Connect the Tractor Harness to ‘Connector 1’ on the Spray ECU. The Tractor Adaptor Harness connects to the Spray ECU and takes the harness as far as the drawbar of the tractor or vehicle, where a breakaway is attached so the vehicle can be easily detached from the trailing sprayer. Lead the harness from the Spray ECU to the back of the vehicle. Care should be taken running the tractor harness from the Spray ECU back cable tying where possible. Do not cut or splice the harness, all excess cable should be strapped away to avoid vibration and wear.

6. Securely mount the Breakaway connector above any hydraulic outlets to reduce the risk if oil ingress to the connectors. (Do not expose the connectors to high pressure water or oil)

7. Connect the Tractor Adaptor Harness to the existing Sprayer Harness.

8. Refer to the ZYNX Console’ manual for the installation procedures for installing the ZYNX Console to the vehicle, if required.

9. To complete the installation go to Section 1.5 to connect the Spray ECU Power/Comms harness to the battery.

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General Layout of fitting a Spray ECU 30S to an Existing KEE Spray Controller

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Figure 12: General Layout of Spray ECU connecting to existing KEE Sprayer Harness

1.4 REPLACING EXISTING RAVEN CONTROLLER WITH A SPRAY ECU 10SR OVERVIEW

The 10SR Spray ECU have been pinned to allow direct replacement of some of the Raven 4xx, 6xx, 4400 and 4600 series controllers. Generally most 4xx, 6xx and 4400 series controllers with inbuilt section switches can be replaced with no need for adaptors. Connector 1 is used for the 4400 series, Connector 2 for 4600 series and connector 3 for the 4xx and 6xx series controllers. Direct PWM control is not possible with direct connection to the Spray ECU. Adaptor looms will be required.

It is important to note that

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all Raven 37 and 16-pin connectors are pinned alike. Subtle differences do occur in some looms so it is extremely important to confirm the pin locations and functions are the same as the Spray ECU before connection as damage can occur. Locate the Raven console harness part number (E.g.115-0159-xxx) and use the relevant Raven console harness wiring diagram to help confirm the pin locations. If the pins and functionality are not the same as the ECU do not connect to it. Contact your KEE dealer and confirm if an adaptor for this application is available.

Note: that damage will occur if any external power is applied to the section drive outputs on the Sprayer ECU. Follow this procedure before installing the ECU to ensure that damage is avoided.

SWITCHES ON EXISTING CONTROLLER

1. With ignition key on, check each section drive output pin on the existing Raven console harness for voltage (use DMM test procedure below). Locate where voltage is supplied from to determine if it can be removed without limiting existing functionality.

2. If it is not possible to remove this voltage then you must install a Section Drive Output Protection Adaptor.

(A2812 for 37-pin on Connector 1 and A2813 for 16-pin on Connector 3)

ANY EXTERNAL SWITCHES SEPARATE TO EXISTING CONTROLLER

(E.g. Joystick and dash board switches) Replacing 4xx, 6xx, 4400 and 4600 controllers that use external section switches is possible however the following steps MUST first be confirmed prior to installing of the ECU.

1. Determine if it is possible to disconnect the existing switchbox without limiting existing functionality (e.g. Boom Lift, Lower or Fold).

2. If yes, disconnect the switchbox, switch the ignition key on and check each Section Drive Output pin on the existing Raven console harness for voltage. If no voltage is present continue with installation.

3. If no, and voltage is present and cannot be removed then you must install a Section Drive Output Protection Adaptor between the ECU and the existing tractor harness.

(A2812 for 37-pin on Connector 1 and A2813 for 16-pin on Connector 3)

4. With all of the section switches in the off position confirm that each section pin on the Raven harness does NOT have continuity to Gnd. If Gnd exists on any of these pins with the section switches in the off position, and the switchbox cannot be disconnected. DO NOT proceed with installation.

5. If external switches must remain connected they must always be switched to the OFF position or ASC will not function correctly.

Installing Spray ECU 3 and Spray ECU 10SR

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Installing Spray ECU 3 and Spray ECU 10SR

Digital Multimeter (DMM) Test Procedure

1. Testing voltage on section outputs on Raven Console Harness with switches on. With DMM set to 20vdc insert Gnd probe into Gnd Pin (usually Pin 1) and Positive probe into each section pin. Confirm yes or no to voltage present.

2. Testing for Gnd on section outputs on Raven Console Harness with switches off. With the DMM set to ohms, insert Gnd probe into Gnd pin (usually Pin 1) and positive probe into each section pin. Confirm yes or no to continuity.

Always disconnect the vehicle battery before proceeding with any installation or servicing of the Spray ECU, Tractor, Sprayer or Valve Looms.

IInnssttaalllliinngg tthhee 1100SSRR SSpprraayy EECCUU

1. Before removing the existing controller run the sprayer and record the minimum and maximum pressure and flow rates attainable. Ensure that the system is functioning correctly before removing the controller.

2. Record all of the calibration factors and section width values. These can then be easily transferred to the ZYNX after installation.

3. Remove the controller.

4. Refer to Section 1.1 for mounting the Spray ECU, Power/Comms Harness and Sprayer switchbox

5. Connect the existing Raven Console harness to CONNECTOR 1 or 3 of the Spray ECU.

6. Connect existing Raven Gnd/Radar speed input to the ‘SPEED’ connector on the Spray ECU.

7. Carefully run the power lead to the tractors battery ensuring it is tied away from moving, hot or sharp objects.

8. To complete the installation go to Section 1.5 to connect the Spray ECU Power/Comms harness to the battery.

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System Layout for Spray ECU connecting to an existing Raven console

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Figure 13: General Layout of Spray ECU connecting to existing Raven Sprayer Harness

Connecting the Spray ECU to the Battery

Step 5: Connecting the Spray ECU to the Battery

1. DO NOT attach the wires to the battery terminals until the installation of the Tractor Harness, Sprayer Harness and Valve Harness has been completed.

2. Connect the Power/Comms Harness directly to 12 VDC battery terminals. Refer to Figure 14.

FFoorr ttrraaccttoorrss tthhaatt uussee 2244 VVoolltt bbaatttteerriieess yyoouu MMUUSSTT uussee aa 1122 VVoolltt // 1155

AAmmpp ((mmiinniimmuumm)) iinnvveerrtteerr..

3. Do not connect the Power/Comms Harness to an alternator or starter motor as this may cause interference or power fluctuations or surges and may damage your system.

4. Attached the Red wire to the POSITIVE (+) battery terminal. Attach the Black wire to the NEGATIVE (-) battery terminal, when installation of the sprayer is completed.

5. DO NOT connect the Black wire to vehicle chassis unless an Isolation Switch is fitted to the negative side of the battery.

6. Do not power other equipment from the power cable; other than KEE products.

7. Connection to the battery terminals must be kept clean and tight at all times.

8. The hardware installation of the Sprayer Hardware Kit is now complete.

9. Refer to the ‘Getting Started’ (Section 2.0) and ‘Software Setup’ (Section 3.0) sections of this manual to complete the software setup for the Sprayer.

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Figure 14: Battery Configuration

+ 142 hidden pages