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ROJ PCS W1 Installation, Operation And Maintenance Manual

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PCS W1
Installation
Operation
Maintenance
ORIGINAL INSTRUCTIONS

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Summary of Contents for ROJ PCS W1

  • Page 1 PCS W1 Installation Operation Maintenance ORIGINAL INSTRUCTIONS...
  • Page 2 ROJ reserves the right to change at any time the contents of this manual, without notice. For any technical or commercial problem, please contact your local ROJ dealer or call directly ROJ customer service center. We will be glad to meet your needs.
  • Page 3 PCS W1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL Edition: October 2018 Revision: Direction and Plant: Via Vercellone 11 13900 Biella (BI) Tel. +39 015 84 80 111 Fax +39 015 84 80 209 Email: comm@roj.com www.roj.it...

  • Page 4: Table Of Contents

    GENERAL INFORMATION AND PERFORMANCES ..................1.3 1.2.1 Introduction ..............................1.3 1.2.2 Functional blocks ............................1.3 1.2.3 Acronyms used ............................... 1.4 COMPONENTS OF THE PCS W1 KIT ......................1.5 GENERAL SAFETY INFORMATION ......................1.6 1.4.1 Design Criteria ..............................1.6 1.4.2 Safety Devices and Solutions .......................... 1.7 1.4.3 Warning About Residual Risks ........................
  • Page 5 ORDINARY PREVENTIVE MAINTENANCE INTERVENTIONS IN CHARGE OF THE OPERATOR .... 4.1 MAINTENANCE / REPAIR RESERVED TO SPECIALIZED PERSONNEL ............ 4.2 SPARE PARTS ............................... 4.3 INDEX UPDATES 04/07/2016 Rev. 1.1 20/12/2017 Rev. 1.2 12/01/2018 Rev. 1.3 08/02/2018 Rev. 1.4 22/03/2018 Rev. 1.5 08/10/2018 Rev. 1.6 - ii - PCS W1 Kit...

  • Page 6: Introduction

    European Union and, when necessary, an “Original language” copy of the manual is also provided. 2. The ROJ manuals always contain a “proforma” copy of the EC Declaration of Conformity (or a “proforma” copy of the Declaration of Incorporation of the “Partly completed machinery”...

  • Page 7: Safety

    Machine. CE Identification Plate The ROJ PCS PCS W1 kits are CE marked on the back side of the PCS AP. The CE marking refers to the whole PCS W1 kit. - iv -...

  • Page 8: Compliance With The Directives And European Regulations

    Compliance with the Directives and European Regulations Herein under a summary of the Declaration of Incorporation, prepared in accordance with the requirements of Annex II B to the 2006/42/EC Directive, with which ROJ declares that the following “Partly completed machinery”:...

  • Page 9: Warranty And Responsibility Of The Manufacturer

    Introduction Warranty and Responsibility of the Manufacturer The PCS W1 system described in this manual is designed to be incorporated into agricultural machines and it’s therefore destined to work exclusively in combination with the above machines. The installation of the various system components on the Seed Drill can be...

  • Page 10: General Information

    Manual objectives 1.1.2 This manual has been prepared to supply the users of PCS W1 Kit with the essential information required to: • Correctly install and connect the system components in safety conditions. • Configure the system and program the various operation parameters according to the end-user needs.

  • Page 11: Symbols Used

    The exhausted batteries must be correctly recycled into appropriate containers. DO NOT DISPERSE THE BATTERY IN THE ENVIRONMENT. - 1.2 - PCS W1 Kit...

  • Page 12: General Information And Performances

    1.2.1 Introduction The PCS W1 system is designed to be applied to agricultural machineries such simple hopper of fertilizer spreaders or grain metering devices, in order to replace the mechanical transmission that drives the metering units with electrical motors, that can be controlled by a smartphone or a tablet.

  • Page 13: Acronyms Used

    Essential Health and Safety Requirement of Annex I of Machinery Directive Performance Level (level of reliability of the safety functions) according to EN 13849-1 Analog/Digital Converter Controller Area Network (BUS) Access point Motor with integrated drive - 1.4 - PCS W1 Kit...

  • Page 14: Components Of The Pcs W1 Kit

    General Information COMPONENTS OF THE PCS W1 KIT Figure 1-1 Main components of the PCS W1 Kit TECHNICAL DATA Rated voltage: 12 VDC; Rated current: 6,6 A; Rated power: 80 W Rated speed: 100 rpm Rugged access point module Rated voltage: 12-24 VDC; Rated current: 250 mA;...

  • Page 15: General Safety Information

    1.4.1 Design Criteria The principles introduced by the relevant paragraphs of the following Harmonized Standards have been adopted in the design and manufacturing of the PCS W1 kit: EN ISO 12100: 2010 Safety of machinery - General principles for design - Risk assessment and risk reduction.

  • Page 16: Safety Devices And Solutions

    Any attempt to remove or by-pass the safety measures installed, thus reducing the overall safety level, IS FORBIDDEN. The responsibility for consequent damages to people and/or properties resulting from the non-fulfilment of recommendations will entirely fall upon the user. PCS W1 Kit - 1.7 -...

  • Page 17: Warning About Residual Risks

    ROJ will assume no liability for possible damage to people and/or properties deriving from non-observance of these warnings. Operators shall be properly trained to use the equipment without risk, and must have read and understood the instructions and warnings given in this manual.

  • Page 18: Noise Levels

    1.4.5 Noise Levels The PCS W1 system have been designed and manufactured to reduce the noise to minimum levels during operation. In any case, since the only potential noise sources introduced by the PCS W1 system (gearmotors) are negligible (<70 dBA) with respect to the noise produced by...

  • Page 19: Safety And Reliability Of Control Systems

    Category Inhibition of dangerous movements in case of metering unit guard open The calculation of the PL values and the “SISTEMA” relevant report can be found in the Technical Documentation kept by the manufacturer. - 1.10 - PCS W1 Kit...

  • Page 20: Installation

    For more information, please refer to TD_1406.601_revD.pdf or later revision. 2.1.2 Outlet shaft dimensions The geared motor outlet has a hollow shaft with the following dimensions. Figure 2-1 – Outlet shaft dimensions For more information, please refer to 1061-cid-a.pdf PCS W1 Kit - 2.1 -...

  • Page 21: Fastening Flange Characteristics

    In order to ensure the correct lubrication of the reduction stage, do not exceed the maximum angles indicated on the following figure. Figure 2-2 – Mounting angle limits For more information, please refer to 1061-angle.pdf - 2.2 - PCS W1 Kit...

  • Page 22: Transport Cap

    The motor must be fastened to the flange, using the bushes, bolts M8x80 and standard M8 washers, as indicated on the following figure. It is suggested to lock the bolts with a thread-lock product. Tightening torque: 10 Nm. Figure 2-4 – Details for the motor fastening PCS W1 Kit - 2.3 -...

  • Page 23: Speed Sensor

    Cogwheel individual sensor The speed sensor is implemented using a hall effect speed sensor type Cherry GS102301 (P/N ROJ 50A00174R) and relevant cable (P/N ROJ 05R01400). The sensor detects the speed of a toothed wheel connected to a machine drive wheel.

  • Page 24: Machine Position Sensor

    If one of the connector are not used, close it with the appropriate connector. MACHINE POSITION SENSOR It is an mechanical proximity sensor (P/N ROJ 05R01422) used to define whether the machine is in seeding position (machine lowered) or in transfer position (machine raised).
  • Page 25 The sensor must be connected to the wiring connector indicated with PROXY_MACHINE. During the machine overall operation check, you can confirm the correct operation carrying out the following procedure. - 2.6 - PCS W1 Kit...

  • Page 26: Position Sensor Check

    The box contains the WiFi module and antenna. Install the box so that the flat back surface has a 30mm clearance from metal parts. Violating this precaution will degrade the antenna efficiency, resulting in a reduced or impaired functioning of the PCS W1 Kit - 2.7 -...

  • Page 27: Electrical Connection Diagram

    Installation ELECTRICAL CONNECTION DIAGRAM Figure 2-9 – System connection diagram Codes of the various items are indicated on the following pages. - 2.8 - PCS W1 Kit...

  • Page 28: Main Components

    MACHINE POSITION SENSOR 05R01400 GS102301 SPEED SENSOR CABLE L=2000mm 50A00174R HALL EFFECT SPEED SENSOR GS102301 + NUT 05R01435 MD CABLE - PCS W1 (6 POLES) 05R01423 SIGNAL CABLE-ISO11786 DMD 2.6.2 MD connection Figure 2-10 – MD connection diagram PCS W1 Kit...

  • Page 29: Safety Switch

    The safety switch is not provided with the kit, because the choice depends on the size limits of the machine on which it will be installed. Note: B10d is the reliability parameter declared by the device Manufacturer that corresponds to the number of switching operations guaranteed without errors. - 2.10 - PCS W1 Kit...
  • Page 30 Fuse on 05R01435 cable To fulfil the safety norms, the cable 05R01435 includes a protection fuse ATO 1A (black). This fuse protects the supply of the access point (AP) and the supply to the sensors. PCS W1 Kit - 2.11 -...

  • Page 31: User Manual

    3.4) When the connection is up, launch the app on your mobile device. Led Blue: When the AP is ON an the Wifi network is active, the blue led on the PCS W1 AP will turn ON. PCS W1 Kit...
  • Page 32 User Manual Led Orange: To start with the application functionality press chain button in the center of “Main” page In this condition led orange turn on. - 3.2 - PCS W1 Kit...
  • Page 33 The picture below shows the main web app page. In the following paragraph the different functions will be described. Note that the appearance of the main screen can differ, depending on the motor SW version. See chapter 5.0 for details. PCS W1 Kit - 3.3 -...

  • Page 34: Connection And Configuration Buttons

    Note: to connect to the AP to the motor, press the CAN, press the button. When can connection is active, the yellow led on the PCS W1 AP will turn ON. - 3.4 - PCS W1 Kit...

  • Page 35: Job Information And Settings

    User Manual 3.3.2 Job information and settings PCS W1 Kit - 3.5 -...
  • Page 36 Product density per hectare, configurable by the user. Range [1-1000 kg/ha] Quantity Product quantity per hectare. Configurable by the user. This icon is not available with all motor firmware version. Check chapter 5.0 for more details. - 3.6 - PCS W1 Kit...

  • Page 37: Alarm List

    Note that the hopper will distribute the product even if the button hasn’t been pressed. The buttons control the start and the end of the job recording that will be stored in the job log (see chapter 3.7) PCS W1 Kit - 3.7 -...
  • Page 38 Note that if the error situation persists, the error will remain active and will be shown in the Error icon. If Alarm are present and the Alarm button is pressed , an alarm list section is opened as shown in the picture below. - 3.8 - PCS W1 Kit...
  • Page 39 User Manual Field Function Description Table containing all active alarm together Alarm List table with a suggested solution PCS W1 Kit - 3.9 -...

  • Page 40: Configuration Page

    User Manual CONFIGURATION PAGE The configuration page can be entered by pressing the button. It contains a number of field used to configure the behaviour of the system. - 3.10 - PCS W1 Kit...
  • Page 41 Prefill speed (see below , item e.g. if Prefill speed value is chosen to be 5km/h, than by selecting “Simulated”, the PCS W1 will simulate a working speed of 5km/h). Speed selection This feature is useful in case of faulty speed sensors to be able to continue to work.
  • Page 42 “Prefill time” seconds then it will start following the tractor The tractor must start driving slightly before the prefill time expires (see chapter 3.7 for explanation) - 3.12 - PCS W1 Kit...

  • Page 43: Software Update

    Allows to save current settings and recall them when necessary (see Chapter 3.9) Network name New name (SSID) for the wifi created by the PCS W1 AP. password New password for the Network. Software update menu Allows to update Access Point and MD...
  • Page 44 Pulse/100 calibration Once the start button is pressed, the user shall travel 100m and then stop. During the travelling, the wheel sensor will count the pulses and provide the correct number of pulses per 100m. - 3.14 - PCS W1 Kit...
  • Page 45 The app will automatically calculate the capacity per revolution of the metering wheel. Note that the calibration procedure is stopped automatically after 60s if the user doesn’t stop it before. PCS W1 Kit - 3.15 -...
  • Page 46 3.7.3 Prefill mode “Automatic” If the Prefil Mode “Automatic” is selected, the prefill is executed automatically after each transition from transport position (machine lifted) to working position (machine lowered), without the need to press the button - 3.16 - PCS W1 Kit...
  • Page 47 Each job correspond to a line on the table, which shows the summary of the job. The following information are stored • Start date • Stop date • Area covered • Total (estimated) weight of distributed product PCS W1 Kit - 3.17 -...
  • Page 48 If pressed, go back to the main page Adds a new row with the current settings. The operator is required to enter the name of the product / name of the settings. “+” button - 3.18 - PCS W1 Kit...
  • Page 49 Selecting the line, will open a windows with the summary of the relevant parameters that will be set. Select/delete calibrations Pressing “Apply” will load the selected settings into the PCS W1. Delete: swiping a row will allow to delete it. PCS W1 Kit - 3.19 -...
  • Page 50 Same as the one in main page. See chapter Error button 3.3.1 (item 12) Actual motor speed at distributor shaft (i.e. after Motor Speed the whole gearbox chain, as specified in the Gearbox Ratio field) - 3.20 - PCS W1 Kit...
  • Page 51 Motor torque as % of its nominal. E.g. 50% Torque indicates that the motor is working at half its nominal torque Battery voltage Voltage measured at motor input [V] Linear conversion factor (debug parameter) PCS W1 Kit - 3.21 -...

  • Page 52: Alarms

    16384 AP heart beat missing Check AP cable connection. Check battery voltage Let motor cool down. Check mechanical arrangement to check that there aren't unwanted frictions, damage 32768 PCB high temperature warning bearings, etc. - 3.22 - PCS W1 Kit...
  • Page 53 (PCS W1 version) and the app version. Make sure to download the latest app from Apple Store or Google Play Store, searching for PCS W1. The version of the app at the date of release of this manual is 1.1.2 The following functions are conditioned on the SW versions: •...
  • Page 54 If you reach the following page, then you can determine the version on the lines “PCS W1 versions” and “MD versions”. 5.2 Compatibility table The following table summarizes which features are available on the PCS W1, depending on the SW versions you own (see 5.1). - 3.24 -...
  • Page 55 X.0.0 >=A.2.2 >=A.2.6 Note that first generation PCS W1 versions or the one with MD version X.0 can’t be upgraded to support the features indicated above. The other versions can be upgraded to support all features. Please contact your local dealer of ROJ’s customer service (mechatronics@roj.com) for further details..

  • Page 56: Maintenance And Troubleshooting

    4 – MAINTENANCE AND TROUBLESHOOTING GENERAL INSTRUCTIONS ABOUT MAINTENANCE WORKS Thanks to its intrinsic sturdiness of the PCS W1 system components, heavy preventive maintenance works are not required. However, to guarantee high reliability levels and avoid hazard conditions, it is advisable to scrupulously read the instructions and warning listed hereunder.

  • Page 57: Maintenance / Repair Reserved To Specialized Personnel

    PARAMETER RANGE PCSW1 Range Units Commercial name -10000 10000 Gear ratio 500000 Pulse/100m Machine Width kg/dm³ Density 1000 kg/ha Quantity 0,01 4000 cm³/turn Capacity Prefill Time 0,036 32,4 km/h Prefill Speed Speed set point - 4.2 - PCS W1 Kit...

  • Page 58: Spare Parts

    PCS MD-O 54T00991R PCS W1 AP 05R01422 MACHINE POSITION SENSOR 05R01400 GS102301 SPEED SENSOR CABLE L=2000mm 50A00174R HALL EFFECT SPEED SENSOR GS102301 + NUT 05R01435 MD CABLE - PCS W1 05R01423 SIGNAL CABLE-ISO11786 DMD PCS W1 Kit - 4.3 -...
  • Page 59 Maintenance and Troubleshooting Page intentionally left blank - 4.4 - PCS W1 Kit...
  • Page 60 DISTRIBUTOR ISO 9001 Certificates by DNV from 1996 ISO 9001:2008 Certificates in 2009 Via Vercellone 11 13900 Biella (BI) Tel. +39 015 84 80 111 Fax +39 015 84 80 209 Email: comm@roj.com www.roj.it REV. 1.6 E – 10/2018...

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