installation and operators guide - irrigation supplies australia ......for sales or technical...

Our policy is one of continue research and development in the quest to improve our products. We therefore reserve the rights to amend information provided in this document, without notice.

For sales or technical support please contact Irri-Gator Products (Pty) Ltd at: Tel: +27 21 9827561, Fax: +27 21 9814473, E-mail: [email protected]

P. O. Box 889, Brackenfell, 7561, Western Cape Province, South Africa (V1.00)

Ferti-Gator™ SOLO system - Installation and Operators Guide

This guide relates to the installation and operation of the Ferti-Gator™ SOLO being a compact, simple and modular fertigation control system for use in both greenhouses and open field irrigation applications. PRINCIPLE OF OPERATION Ferti-Gator™ SOLO has been designed to accurately inject plant nutrients or other chemicals into the irrigation water using a single venturi type fertiliser injector. By varying the motive flow through the venturi injector unit, the injection rate (suction) of liquid fertiliser can be controlled. A change in flow is achieved by regulating the speed of the booster pump using a variable speed drive fitted to the pump’s electric motor. The control of the injection process can be performed in one of several manners including; proportional injection of fertiliser to irrigation water (flow-on-flow), volumetric

injection or by EC or pH targets (set points). The electronics in the Ferti-Gator™ SOLO system control these parameters and automatically adjust the pump’s performance to match the required injection rate. The Ferti-Gator™ SOLO system can be used as an independent (stand-alone) fertigation machine which can be operated in hand mode, controlled by external irrigation controller in auto mode or fully integrated with the iGator™ PC based Irrigation Control System. NOTES ON SAFETY

Read this document thoroughly and follow instructions as set out in this document. Make certain any power source connected to the unit is fully isolated before accessing any electrical

enclosures to carry out the installation or maintenance processes. Before attempting any installation or maintenance work on the injector’s or pipe work, close all manual

valves at the fertiliser tank outlet and depressurise the system. A qualified electrician is required to carry out any electrical connections above 30 Volts AC. Make certain the unit is grounded (less than 1Ω resistance measured between the unit and ground)

before applying any power to the unit. The Ferti-Gator™ SOLO system has been designed to inject dissolved chemicals. Some of these

chemicals can be dangerous when in contact with the skin or when inhaled. To prevent this, use protective eyewear, rubber gloves and gas mask as is required.

Follow all applicable local regulation relating to the storage and handling of chemicals.





MAIN SYSTEM COMPONENTS A standard Ferti-Gator™ SOLO unit consists of the following components or sub-assemblies:

The venturi injector assembly, comprising of the venturi

injector unit, a manual diaphragm valve, a flow sensor with electronic pulse output, a rotameter (variable area flow meter), a non return valve and a flexible suction hose assembly with inlet and outlet fittings.

The inlet pipe work (upstream of the venturi injector). The outlet pipe work (downstream of the venturi injector). The booster pump. The control panel comprising of the HMI (Human Machine

Interface), system electronics and the pump’s motor controls. The aluminium support frame assembly.

ASSEMBLING THE UNIT In most cases the Ferti-Gator™ SOLO unit should be fully assembled requiring only plumbing to the irrigation main line, connection to the liquid fertiliser or chemical supply tank and to be provisioned with a suitable power source. If the unit is not fully assembled, follow these steps –

1. Assemble the aluminium frame using the pre-cut aluminium sections and the fasteners included in the pack by following the frame assembly instructions provided.

2. Mount the booster pump on to the frame using the four bolts supplied. Note that the outlet of the pump (delivery side) should face away from the frame assembly. Do not tighten the holding bolts at this time.

3. Attach the outlet flange to the booster pumps outlet using the rubber flange packing and the four bolt/nuts provided.

4. Attach the pipe work which has been provided between the venturi injector’s downstream union and the booster pumps suction inlet flange. Clip this pipe work into the holding saddles on the frame. Use the rubber flange packing and the four bolt/nuts provided.

5. Attach the inlet pipe work which has been provided to the venturi injector’s upstream union. Clip this pipe work into the holding saddles on the frame.

6. Mount the control panel which houses the HMI, electronics and motor controls onto the frame using the fasteners provided.





POSITIONING THE MACHINE Position the Ferti-Gator™

SOLO unit on its feet on a flat solid surface which will remain clear of standing water or fluid and under a roof (the unit is not rain resistant). Attempt to locate the machine with acceptable clearance around it to make movement possible when servicing the machine in the future (see Figure 1).

PLUMBING THE UNIT INTO THE IRRIGATION SYSTEM

The Ferti-Gator™ SOLO unit is equipped with 1” female threaded BSP inlet and outlet ports as noted in Figure 2. Two of 1” off take points should be made available on the irrigation mainline spaced between 0.8 and 1.0m apart as noted in Figure 3. It is highly recommended that these off take points are fitted with isolation valves allowing the system to be completely isolated for future maintenance without the need to shut the main irrigation system down. It is also highly recommended that non return valves are fitted to these two off take points as noted in Figure 3. In systems where the inlet pressure may exceed 8.0 bar, it is most

advisable to install a pressure reducing valve on the inlet to the system and to set this valve at 5.0 bar. This valve can be either a direct acting pressure

reducing valve or a conventional hydraulic valve fitted with a pressure reducing pilot valve. Note!!! Keep the pipeline lengths between the off take points on the

irrigation mainline and the Ferti-Gator™ SOLO units ports as short as practically possible to avoid generating excessive head loss. CONNECTING THE FERTILISER SUPPLY LINE It is recommended to place the liquid fertiliser supply tanks on an elevated surface at a minimum of 300mm above the floor level thus ensuring that the supply pipework (suction intake) to the Ferti-Gator™ SOLO is below the tanks outlet. This also eases the installation of the tanks outlet isolation valve and outlet filter which we highly recommend is fitted to each tank as seen in Figure 4 below.

Keep the length of the pipework between the tanks outlet and the Ferti-

Gator™ SOLO suction inlet as short as practically possible. If the transparent reinforced flexible PVC hose that is supplied with the unit is too short to connect to the fertiliser tank directly, make use of a high class (high

pressure rating) rigid PVC pipe with a diameter of DN25 or DN32 to make up the shortfall.

Figure 1

Figure 2

Figure 3

Figure 4





ELECTRICAL CONNECTIONS

Ferti-Gator™ SOLO machines are available in two voltage versions namely: 230 Volt AC single-phase or 400 Volt AC 3 phase. The mains supply connection terminals are the only difference between the two machine models. Each machine is equipped with a row of electrical terminals as shown in the two terminal schematics below.

Available connecting terminals in the 230 VAC single phase machine

Available connecting terminals in the 400 VAC three phase machine

Mains Supply Connection The mains supply electrical power connection to the Ferti-Gator™ SOLO unit should be carried out by a qualified electrician and failing to do so could deem the product warranty null and void. It is important to note that a neutral is required as well as the three phases on the 400VAC machine. If this is not available your electrician will need to install an additional transformer using two of the three phases to achieve 230VAC single phase power source. NOTE!!! Do not use one of the phases and the earth to obtain 230VAC single phase. For system protection purposes it is vital to have a separate earth and neutral. NOTE!!! Proper earth connections are extremely important! Motor Connection In most cases the Ferti-Gator™ SOLO unit should be fully assembled and as such the motor should already be wired to these terminals. If this is not the case, please consult with an Irri-Gator Products technician before you proceed.





Inputs

The Ferti-Gator™ SOLO unit has three back indication inputs – the system water meter, the unit’s fertiliser meter and an analogue input for an EC or pH monitor. These meters are to be wired as follows –

The system water meter – The Ferti-Gator™ SOLO unit has been designed to work with any conventional water meter that provides a pulse type (reed switch) output. The water meters pulse output ratio to unit of measurement must be set in the machine’s setup. Connect the water meters pulse output cable (also known as EV or EPC) to terminal 1 (+24VDC) and terminal 4 (Water Meter) as shown in Figure 5. The system fertiliser meter – The Ferti-Gator™ SOLO unit has been designed to work with a high speed pulse type frequency (standard on machine) or any conventional fertiliser meter that provides a pulse type (reed switch) output. The fertiliser meter’s pulse output ratio to unit of measurement must be set up in the machine’s setup. See Figure 6 for connection of the high speed pulse type input and Figure 7 for the conventional fertiliser meter wiring. Analogue device – Both externally powered or loop powered 4-20mA devices can be used to connect to the Ferti-Gator™ SOLO. EC and pH monitors supplied by Irri-Gator Products will be of the externally powered type – see Figure 8 for connections of externally powered devices and Figure 9 for connections of loop powered devices. NOTE!!! Check analogue device and high speed pulse meter connections’ polarity before powering up!

Auto Set Point Inputs The Ferti-Gator™ SOLO has five set point (recipe) selection inputs that can be triggered by any potential free relay contact when in Auto Mode. This allows the unit to be remotely activated by any irrigation controller, timer device or simple toggle or other switch with potential free contacts. See Figure 10 for wiring of Auto Set Point Inputs. NOTE!!! Only connect a potential free contact to the Auto Set Point Inputs. Additional relays will be necessary to interface any live output (e.g. from a standard irrigation controller).

Ouputs The Ferti-Gator™ SOLO has four NO (Normally Open) potential free output sets for signaling and control of optional auxiliary devices. See Figure 11 for wiring of Outputs.

System Running (Terminal 12 & 13) Fert Main Valve (Terminal 14 & 15) Tank Mixer (Terminal 16 & 17) System Alarm (Terminal 18 & 19)

NOTE!!! Output Contact Ratings: Resistive Load 10A/Inductive Load 2A

AC Max 250V/DC Max 110V

Figure 5 Figure 6 Figure 7 Figure 8 Figure 9

Figure 10

Figure 11





PROGRAMMING THE UNIT HMI Navigation

System Setup Injector Setup Menu

Pulses / l : Fertiliser meter pulse:unit ratio. How many pulses does the fertiliser meter give for each 1 liter of dissolved fertiliser injected? Reset: Factor used to calculate time before resetting fertiliser flow if no pulses are received. Mode: Select injection mode.

Mixer Output Menu

Hand/Off/Auto Selector

Manual Recipe Selection

Alarm Scroll Bar

Recipe Menu

System Setup Menus

Irrigation Cycle Logs

Event Logs

Tap to open new screen

Tap to change or select

Mode

Tap to open next screen Tap to close screen

Tap on a value to open virtual keypad for editing.

Tap Enter on keypad to save value.





Mode Description

Flow-on-Flow Flow-on-flow proportional injection mode. Set point set in recipe (set in l/m3) is used to proportion fertiliser injection rate according to main line flow rate.

EC Control PID injection mode where system will adjust the fertiliser injection rate according to an EC (Conductivity) level set by the user. Analogue feedback from an EC monitor required.

pH Control PID injection mode where system will adjust the fertiliser injection rate according to a pH (level set by the user). Analogue feedback from pH monitor required.

Normal (l) Volumetric injection mode where the user define a volumetric amount of fertiliser to be injected in liters. No proportioning takes place.

Normal (min) Volumetric injection mode where the user define the duration of constant fertiliser injection in minutes. No proportioning takes place.

PID Kc & PID Ti: Used to calibrate reaction times for Flow-on-Flow and PID modes. No Pulse Del (s): While system is running, this delay will determine how long the system should wait for

fertiliser pulses before triggering a “No Fert Pulse” alarm. Time set in seconds. Set to “0” to disable this function. Uncontrol Pulses: Number of pulses allowed to register while the system is not active before triggering an

“Uncontrolled Fert” alarm. Set to “0” to ignore. Alarm %: Used in Flow-on-Flow and PID modes to activate a warning if flow or analogue feedback (EC or pH

levels depending on mode) is out-of-range. Alarm Del (s): Delay before out-of-range warning triggers. Set to “0” to disable out-of-range warnings. Stop %: Used in Flow-on-Flow and PID modes to stop injection if flow or analogue feedback (EC or pH levels depending on mode) is out-of-range. Stop Del (s): Delay before out-of-range values stops injection. Set to “0” to disable.

Water Meter Setup Menu

Pulses / m3 : Water meter pulse:unit ratio. How many pulses does the water meter give for each 1 m3 of water

irrigated? Reset: Factor used to calculate time before resetting water flow if no pulses are received. No Pulses Del (s): While system is running, this delay will determine how long the system should wait for water pulses before triggering a “No Water Pulse” alarm. Time set in seconds. Set to “0” to disable this function.

Tap to open next screen Tap to close screen



Mode





Set Time Menu

Set time and date for logging purposes. Tap red button to reset water and fertiliser accumulation.

Recipe Setup Flow-on-Flow Injection Mode

Up to 5 recipes can be set up, in each recipe:

- Expected Water Main Line Flow Rate (m3/h): This enables the system to start injection even before a true flow rate is registered.

- Injection requirement (l/m3): Required amount of dissolved fertiliser to be injected expressed in liters (l) of fertiliser per 1000 l (m3) of water.

- Water Before (min): Wait time at start of cycle (in minutes) before fertigation is activated. EC Control Mode


- Required EC: EC (Conductivity) set point to target. Feedback from an analogue EC monitor is required. - Water Before (min): Wait time at start of cycle (in minutes) before fertigation is activated.

Mode

Mode

Mode

Tap to close screen







pH Control Mode


- Required pH: pH set point to target. Feedback from an analogue pH monitor is required. - Water Before (min): Wait time at start of cycle (in minutes) before fertigation is activated.

Normal (l) Mode


- Required l: Amount of fertiliser to inject in liters (no proportioning). - Injection rate l/h: Rate at which injection should take place (limited by system hydraulics). - Water Before (min): Wait time at start of cycle (in minutes) before fertigation is activated.

Normal (min) Mode


- Required min: Duration to inject fertiliser in minutes (no proportioning). - Injection rate l/h: Rate at which injection should take place (limited by system hydraulics). - Water Before (min): Wait time at start of cycle (in minutes) before fertigation is activated.

Mode

Mode

Tap to close screen



Mode





Tank Mixer Setup

Start hr: Time of day to enable mixer operation. Stop hr: Time of day to disable mixer operation. Run (sec): Mixer on time in seconds. Wait (min): Mixer off (wait) time in minutes.

Manual Start/Stop Mixer by tapping on

Tap to close screen







ALARMS AND LOGS Alarms

Alarm Troubleshooting

Low EC Alarm / Stop EC Control Mode Only. Check venturi for suction

o Check booster pump o Check venturi for obstruction

Check chemical supply o Check chemical tank level o Check chemical filter o Check chemical shut-off valve o Check chemical line for obstructions / airlocks o Check chemical solution

Check / calibrate EC monitor

High EC Alarm / Stop EC Control Mode Only. Check fertiliser solution Check / calibrate EC monitor

Low pH Alarm / Stop pH Control Mode Only. Check chemical solution Check / calibrate pH monitor

High pH Alarm / Stop pH Control Mode Only. Check venturi for suction


Check chemial supply o Check chemical tank level o Check chemical filter o Check chemical shut-off valve o Check chemical line for obstructions / airlocks o Check chemical solution

Check / calibrate pH monitor.

Low Fert Flow / Stop Flow-on-Flow Mode Only. Check venturi for suction



Check chemical flow meter, EV/EPC and wiring. Check VSD settings

High Fert Flow / Stop Flow-on-Flow Mode Only. Check chemical flow meter, EV/EPC and wiring. Check VSD settings

VSD 1 – ER.xxx Please consult the Senlan SB200 VSD manual. Only reset VSD error if safe to do so.

Uncontrolled Fert Alarm Check chemical shut-off valve

No Fert Pulse Alarm Check venturi for suction o Check booster pump o Check venturi for obstruction


Check chemical flow meter, EV/EPC and wiring. Check VSD settings

No Water Pulse Alarm Check irrigation system / pump / flow meter, EV/EPC and wiring.

Please see SYSTEM SETUP for alarm options and settings.





When an alarm is triggered, the following occurs:

will be displayed on the HMI The alarm type is displayed in the Alarm Scroll Bar A relay contact is activated

To cancel the alarm and restart the system, tap on To cancel a VSD alarm, push RST on VSD when safe to do so. Alarm Logs To view historical alarms, tap on the Alarm Scroll Bar

Irrigation Logs

Tap to close screen





Event Logs

Tap to close screen





OPERATING THE SYSTEM Manual Operation (Hand Mode) – Start Fertigation

Tap H/O/A Selector switch as to set it in “H” position

Tap the required Recipe

Activated Recipe indicated in Green

Manual Operation (Hand Mode) – Stop Fertigation

Tap on Activated Recipe indicated in Green to stop

No Recipes active

Automatic Operation (Auto Mode) – Start Fertigation

Tap H/O/A Selector switch as to set it in “A” position

Apply a contact from an external controller or device to required Auto Set Point / Recipe Input.

Automatic Operation (Auto Mode) – Stop Fertigation

Disconnect contact from an external controller or device from Auto Set Point / Recipe Input. OR

Tap H/O/A Selector switch as to set it in “O” position (Off)

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