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Service Manual TS-T Date December 2015 Subject EC Remote & Flowmate Control Place Kverneland Group Nieuw Vennep Hoofdweg 1278 2153 LR Nieuw Vennep The Netherlands Details Technical Service Manual...
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1. System overview EC remote control The EC system is a non-regulating system. 1.1 EC remote control box In the tractor is a control box fitted which communicat through a On/Off LED splitter board directly to the functions. Tractor Machine box Functions Water function switches...
2. Elements of Flowmate Control FMC-R Tractor Front Back Extra SHC box/Splitter box: • For some sprayers there are not enough Hydraulic connection on the first SHC PCB (Section and Connection cable to Connectors Hydraulic Control). In that case an extra SHC water valves and PCB must be fitted.
2.1 Control box Front side Presure: Selection touch keys Spraying: Home switch Return agitator: Sections: AUTO (9 sections + 2 border nozzles) Hydraulics: • Pre- selection system Activate Inactivate • Oil circulation system Up / in - Neutral Down / out...
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2.1 Control box Rear side Main switch: I = On 0 = Off II = No function Connection for: • Speed cable Connection for CAN • Speed adaptor cable (from splitterbox)
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2.1.1 Controlbox inside Connector For connection to other PCB Version till 2005 0,25 mm2 display Display connector keyboard Backlight connector keyboard connector...
2.2.1 Power & battery Cable The power cable provides the complete system with electrical power. The connector can be put into the 12V plug on the tractor or to the special battery cable To prevent electrical problems make sure the connectors are clean and without damage. 12V + 0 V - Brown +...
2.2.2 CAN Cable The CAN cable connects the FMC control box via the Splitterbox to the rest of the machine. The CAN cable can be connected to the FMC control box by the black connector plug. CAN cabel Pos. Colour Contact connector Brown...
2.2.3 ISO Connection cable: between Splitterbox & SHC-box The ISO cable provides power and communication to the Section & Hydraulics PCB at the rear of the machine. The thick red & black wires (6mm ) provide the electrical power for the hydraulic valves and section motors. The thin red & black wires (2,5mm ) provide power to the PCB itself.
2.3.1 Flow sensor/Flow meter Most of the sprayers are equipped with a flow sensor. The flow meter measures the amount of spraying liquid from the regulator to < 2014 model the spray line. Therefore the flow meter is always assembled between the pressure regulator and the section valves.
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2.3.1 Flow sensor/Flow meter Checking flow signal Checking flow meter: In screen 14 you can always see the actual flow. (signal from flow sensor) The Flow sensor is fitted in a flow meter housing Inside this house is a wheel. When there floats water through the flowmeter the wheel starts turning.
2.3.2 Slope correction sensor (90°, black) Checking slope correction signal The slope correction sensor measures the angle of the middle frame. The signal of the slope correction sensor is used for the In main screen 1 you can check the signal of the slope correction position indicator in the main screen and the auto center position of sensor.
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Colour Colour Brown + (12 V) Brown + (5 V) Black signal Black signal Blue Blue 12 V slope correction sensor 5 V slope correction sensor • + 12v (brown) connected • + 5v (brown) connected to to test LED port ANA2 port •...
2.3.3 Wheel (speed) sensor For an automatic regulation of the spray quantity, the computer When the speed sensor cannot be fitted on the sprayer (i.e. must know the driving speed. For the trailed machines is in most mounted sprayer) we use a speed sensor with a connector. This cases the speed sensor connected to the SHC print.
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2.3.3 Wheel (speed) sensor Checking speed signal. (trailed sprayer) Checking speed signal. (Mounted sprayer) To check the speed signal there are a few setting in the control box To check the speed signal there are few setting in the control box which which must be checked.
2.3.4 Locking sensor The locking sensor shows the driver that the boom is locked and Check the locking sensor signal ready for folding. When the boom is locked you can see this on The locking sensor only reacts on a magnetic field. It is very your FMC control box by the red LED.
2.3.5 Pressure sensor In some cases sprayers are equipped with a pressure sensor instead of a flow meter (for example semi continue system) The pressure sensor must be connected to the SHC-PCB at position ANA 1. The locking LED must than be connected to the DIG 2 (flow sensor connection) Attention: Check the position of the jumper on the PCB!
SHC Box: output connections Main valve Pressure Presure regulator Spraying Return regulator OPEN agitator ON Agitator valve Hydraulic out. OUT18, OUT17, OUT16 , OUT15 Ect. Section out. OUT 2, OUT 3, AUTO OUT 4, OUT 5 ect.
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2.4.1 Pressure regulator Connector on valve Wire colour Function Pin 1 Brown Positive (+) Pin 2 Green/Yellow Signal Pin 3 No function Ground blue Negative (-) For the cable to the pressure regulator the green/yellow wire has to be cutted off.
2.4.1 Pressure regulator SHC connections Pressure regulator Main valve pressure regulator Agitator valve The SHC position of the main valve is always after the last section right. The pressure regulator is connected as: Brown – Blue +...
2.4.2 Position and connections of section cables b b b b middle section + → permanent plus – → permanent minus – – – – – – – – out 3 out 5 out 7 out 9 out 4 out 6 out 8 –...
2.4.3 Adding border nozzle When a machine has to be equipped with a border or verge nozzle it is important that you connect everything on the correct place. Activating border nozzles is always taking away 2 functions of the SHC card Main valve Pressure regulator To let the regulator...
2.4.4 Position of hydraulic cables Warning: • It is very important that the right outputs are configured in the software. Otherwise most of the functions will not work. For example 1 hydraulic function configured too much oil circulation works only in 1 direction!
2.4.6 Connection cables for hydraulic valve The hydraulic cable connects the hydraulic valves to the SHC PCB. Hydraulic cable Pos. Colour Contact Brown + (12V) Blue signal...
2.4.7 Connection cable oil circulation valve The oil circulation valve has two functions: • Opening and closing of the oil circulation valve • Changing the direction of the oil flow: Left / Right valve (example folding IN or OUT) The oil circulation cable is always connected to the 2 slots after the last hydraulic function on the SHC PCB. The brown cable is connected to the continuous PLUS, the other 2 signal cables are connected to first following 2 empty SIGNAL slots.
Connections for 2 SHC - Boxes When the sprayer is equipped with more then 18 output functions, there are not enough slots on the PCB. On existing machines this can happen after adding extra functions like sections, boarder nozzles, independent slope correction or independent folding. In that case, we split up the water/section and hydraulic functions and equip the sprayer with a second SHC box via an extra Splitterbox.
2.5.1 Extra Splitterbox for 2 SHC boxes •The splitterbox together with a 2 SHC box is fitted on a machine when more then 18 functions are needed •When later extra functions are added: extra splitterbox + SHC can be ordered as set. •With 2 SHC boxes, water and hydraulic functions will be separated and get their own box •PCB has POWERtest LED...
Connections Automatic steering system • The optional auto steering system is located in the Mini I/O 2.6.1 Splitterbox with steering system module or STC (Steering Controller) • It’s power and communication cables are connected in the front splitterbox The PCB has 3 possible connection slots for options Wire plan for the Power &...
2.6.2 Power cable steering system mini I/O Left Connection Right Cable letter. Colour/number Pos on connector Brown Blue Brown Blue Steering valve connector Left Steering valve connector right Power and communication cable Yellow/green Yellow/Green...
2.6.3 Sensor cable mini I/O The Mini I/O steering system works with 3 sensors: Warning: • Boom in sensor (12V) • Make sure you connect the right sensor to the right cable • 180 degree sensor (5V or 12V) because of the difference in voltage •...
2.6.4 180 Degree sensor There are 2 different 180 degree sensors, 5V and 12 V. 12 V 180 degree sensor 5 V 180 degree sensor Machines produced before 11-2014 are equipped with 5 V sensor (light blue) Machines produced after 11-2014 are equipped with 12 V sensor (dark blue) The mini I/O is ready for an 5 V sensor or for an 12 V sensor.
ASV (Automatic Suction Valve) Hydraulic Connectors Connection cable to water valves and hydraulic valves SHC Box Splitter CAN Cable Control box Power cable...
2.7.2 ASV inside Important Please check the jumper positions: • Mounted Jumper placed • Trailed Jumper removed...
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2.7.3 ASV inside There are 2 different 180 degree sensors, 5V and 12 V. 12 V 180 degree sensor 5 V 180 degree sensor Machines produced before 11-2014 are equipped with 5 V sensor (light blue) Machines produced after 11-2014 are equipped with 12 V sensor (dark blue) The ASV pilotbox has 2 connection places for 180 degree sensors (5 V and 12 V).
2.7.4 ASV Cables The potential meter for the level indicator is connected by a separate cable Connector Wire Brown Green /Yellow Blue Connector Wire Brown Green /Yellow Blue Connector Cable colour Connector Cable colour number number number number black Cut away black Cut away black...
2.7.5 Suction valve motor The ASV suction valve is due to different valve positions not the same. The difference is the switch plate in combination of the Green pos 1 position of the micro switches. The electronically diagram and Pink pos 2 connections are the same Brown pos 3 White pos 4...
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2.7.5.1 Trailed machines. Ikarus S and 2.7.5.2 Mounted Ixter Ixtrack Clean water tank Main tank Suction Main hose tank connector Clean function water tank Drain function When the function drain is selected the Suction hose red Arrow on the connector valve is between the main tank and the drain...
System testing possibilities Sensor - test: 3.1 Controlbox and switches → radar sensor (W = 0) R = 1 → wheel sensor, speed adapter (no radar W = 1 Switch on the control box and press directly. sensor) (R = 0) Buzzer test: →...
SHC –box Standard: + (plus 12V) test: green and red test LED are burning. • connect a single cable to „S“ at test position and to „+“ at an other position red LED is burning This means also: • If there is a single cable only connected at position “S”...
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SHC –box – (minus) test: „S“ signal test: • connect a single cable to „S“ at test position and to „–“ at an • connect a single cable to „S“ of test position and „S“ of an other other position green LED is burning position and activate additionally the according switch of the other position.
Cable and sensor test Example hydraulic cable: Disconnect the single cable from the working position and bridge connect it to „S“ of the test position. Connect position 1 and 2 of the plug to each other with a separate single cable (bridge). →...
FMC-R screen information including parameters Attention For the parameters only look to the parameter list and search for your model do not fill in the values shown in the screen. 1) Sections (on/off) Field registration 1) Quantity in tank 2) Auto/man mode 2) Ltr.
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FMC-R screen information including parameters Default: Default: Default: Default: Mtr. • Fill in tank volume Calibrate the slope correction 5 Liter (depending on machine and confirm with OK configuration) • 100 l Explanation screen: Eplanation screen: Explanation screen: Explanation screen: Normal tank volume Tank low alarm.
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FMC-R screen information including parameters Default: Default: Default: default: Border nozzle Yes/No Calibrate flow sensor • SimStart : 1 (from FMC 1,20) Fill in the section length (depending on machine • Vsim: 8 km/h (depends on machine configuration) • Q+/-SC : 0 configuration) Explanation screen: Explanation screen:...
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FMC-R screen information including parameters Default: Default: Default: Default: Choose flow sensor or Information Fill in the information of 100% Pressure sensor (Depends unknown nozzle (depending on machine configuration). on the machine) Explanation screen: Explanation screen: Explanation screen: Explanation screen: P= Pressure sensor With this information of the Quick adjust for flow meter.
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FMC-R screen information including parameters Defaultr: Default: Default: Parameter: Calibrate the Limit Information (screen only • Calibrate sensor • DZ Δ D Axle 50 cm • 0 • axle gnl,gnr 0.70 visible when connected Δ D Drawbar 0 cm • Calibrate sensor •...
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FMC-R screen information including parameters Default: Default: Default: Wheel steering: Always 100% information DB Phoenix DB Ikarus axle Explorer A :40 Drawbar steering: B :65 IkarusS 150-170 track C :55 IkarusS >170 track 100% D :35 Ixtrack 150-170 track Ixtrack 170-190 track E :35 Ixtrack...
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FMC-R screen information including parameters Default: Default: Default: Default: 50 cm Sensor output information 2 way valve Calibrate pressure sensor Explanation screen: Explanation screen: Explanation screen: Explanation screen: The distance between the In 1 = rear sensor output Type of section valve Check chapter 4.8 nozzle In 2 = front sensor output...
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FMC-R screen information including parameters Default: Default: Default: Default: Rev D No reg 0.8% 2 sec. Sp 50% (speed) P zone P zone Fl 20% (flow) T on 50 ms T on 50 ms PR20% (pressure sensor) T off 100 ms T off 100 ms Al2 sec alarm delay time...
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FMC-R screen information including parameters Default: Default: Default: Default: Fill in the right hose 7 sec Information Fill in the right hose length/diameter length/diameter Depending on the machine Depending on the machine configuration configuration Explanation screen: Explanation screen: Explanation screen: Explanation screen: PD1= Pump to regulator KPD= suctionvalve/pump...
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FMC-R screen information including parameters Default: Default: Default: Default: Fill in the right hose Fill in the right diameters Fill in the right hose length Fill in the right hose length length/diameter Depending on the machine Depending on the machine Depending on the machine Depending on the machine configuration...
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FMC-R screen information including parameters Default: Default: Fill in the right hose length Depending on the machine configuration. Explanation screen: Explanation screen: Section valve to sprayline Always leave the setup length functions by the flag otherwise the values will not be saved!!!!
Special Alarm screens Please notice after updating to FMC 1.14 or higher the STC software must always be up-dated to 1.05. (if not you get this alarm all the time) On of the steering potentiometers is out of its theoretical range. This means one of the potentiometers is broken.
Calibrate slope correction • The display (M) for the position of the hydraulic hillside Mode of procedure: correction on the display of the operating unit must now also be • Put the hydraulic hillside correction into the central position by precisely in the central position.
Calibrate speed sensor (Wheel or Radar) If the impulse values for a certain measurement distance is already known, the two values, measurement distance and matching number of impulses, can be input directly (e.g. change of tractors in joint use of machines). If the driving speed has to be calibrated, please proceed as Calibrate Wheel speed follows:...
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Calibrate speed sensor (Wheel or Radar) Calibrate radar speed If the driving speed is measured by a radar sensor on the tractor or a Starguide is used, the calibration is done in Screen 13. The number of impulses must be entered manually according to the information in the operating instructions for the tractor.
Calibrate flowmeter Screen 14 contains the calibration of the flow meter. Mode of procedure in "gauging": To calculate the through flow in l/min the spraying computer needs • Fill the sprayer with clear water and set all operating elements the ratio of numbers of impulses to litres. The number of impulses to “Spraying”.
Calibrate unknown nozzle In some cases the nozzle which is used in not in the large library For the customer to select this: first the pre-selection has to be of the spraying computer. done in screen In this case the nozzle information must be putt in the FMC manually.
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Calibrate unknown nozzle Filling in the data. To get the right nozzle information in your FMC there are two possibilities Option 1. Go to your nozzle supplier and ask for the right nozzle information. In most of the cases this nozzle information is enclosed with the nozzle.
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Calibrate unknown nozzle Option 2. In the cases that there is also no nozzle information distributed by the supplier we have to measure the four necessarily values manual. Step 1. Start spraying on manual mode with 3 bar pressure Step 2. Measure 5 different nozzles spread over the total boom wide for 1 minute.
Calibrating pressure sensor Screen 45 contains the calibration of the flow meter. When the measured value on the nozzles is not the same as the To calculate the correct flow/pressure the sensor needs to be calculated flow in main screen 2 make the following adjustment precisely calibrated.
Configure hydraulic functions In §2.4.4 is the position of the hydraulic cables explained. It is very important that the configuration is the same as the wire connections otherwise the hydraulic function will not work. How to adjust. active active active active active AUTO...
4.10 Calibration and explanation steering system For a good track following system it is necessary to calibrate the steering system in a structured way. Please follow the steps below one by one. For more parameter information. The screens correspond with Software Version FMC1.09! On other versions the screen number can be different 1) Put machine, drawbar/ wheels, and tractor in a straight line (Tractor + Sprayer must have the same track width!!!) 2) Check parallelogram 3) Calibrate sensors in the middle position (roughly about 450)
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4.10 Calibration and explanation steering system Step 1) put wheels and drawbar straight behind the tractor • Steer the wheels or drawbar with the switch in manual mode to the middle position. Attention: If the steering system is not reacting follow the instruction below Go to screen 32 and select the LIMIT - When the value is flashing you can always operate the manual mode...
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4.10 Calibration and explanation steering system Step 2) Check parallelogram/position steering sensors Front steering sensor • The steering arm and rod on the sensor must make a parallelogram to the tractor. • In the middle position the sensor arm must be in a 90° angle to the drawbar Rear steering sensor The position of the rear sensor is depending on the machine...
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4.10 Calibration and explanation steering system Step 3) Calibrate center position sensors Go to screen 30. • The middle position of the sensors is about 450 count. Attention: Only the rear sensor of the explorer steering axle from 2006 has approximately 420 counts - Select the 1st value = front sensor and confirm with OK - Select the 2nd value and set to 0 !
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4.10 Calibration and explanation steering system Step 4) Set dead zones to default Go to screen 31 First “big” dead zone is for the track following: • default 10 this means no steering reaction within 10 counts of desired position. •...
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4.10 Calibration and explanation steering system Step 5) Set the GAIN to default The gain is the reaction between the front and the rear sensor. The gain depends on the relation between the pivot points on the sprayer and tractor. •...
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4.10 Calibration and explanation steering system Step 6) set the LIMIT (very important after changing tyres or track width) The LIMIT will restrict the maximum steering angle for safety reasons. (For example wheels touching the tank or tipping over at narrow track width) Go to screen 32: Select the value and steer in manual mode to the maximum allowed angle: CHECK both sides of the machine!
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4.10 Calibration and explanation steering system Step 7) Adjust hydraulic steering speed 12 V = For a good reaction of the sprayer is it important to adjust the 100% hydraulic speed. The speed adjustment depends on the machine configuration • Adjust the oil flow from the tractor to about 25 l/min •...
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4.10 Calibration and explanation steering system Step 8) adjust the MAN LIMIT To prevent the steering system is being activated with folded-in booms, the boom sensor blocks the AUTO track following. In this situation only manual steering is allowed till a certain angle depending on the track width.
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4.10 Calibration and explanation steering system Step 9) adjust GAIN in the field If the basic settings are done it is wise to check the settings in the field and if necessary to fine tune them. Switch to AUTO mode and make sure the booms are folded out. Drive in a circle, the wheels must follow in the track of the rear wheels of the tractor.
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4.10 Calibration and explanation steering system Step 10) Adjust 2 Dead zones in the field The dead zones make the steering system less nervous: the BIG DZ is for track following, the SMALL DZ is for the center position. • If steering reacts to nervous on AUTO mode Increase the first “BIG DZ”...
Software information ASV (Ixclean comfort) Operations screens Fill tank filling by an external hose Drain function. This function is only visible on the Ixter sprayer. Filling by sprayer pump Clean water tank will be pumped in main tank Suction filter cleaning function Exit Additional information The drain function is only visible with the Ixter sprayer.
Software information ASV (Ixclean comfort) Adjustment & calibration screens AUTO 1300 Hold for 2 sec • Volume keys Key Volume • Alarm signal volume Alarm Volume • At how many % alarm is Alarm Level comming up Fill step size Fill step size •...
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Testing screens AUTO Hold for 2 sec 1300 • Test screen (Only LCD Test mechatronics use) • Testing buzzer Buzzer Test • Testing valve function. On Ikarus S not the correct valve position is chooses Valve Test • Sensor counts Level top +/-300 couts Level sensor Level down +/- 700 counts...
Testing screens Calibrating electronic level indicator For a good calibration process please follow up the steps one by one. Step 1. Calibrate your spray flow meters in a correct and precise way. (look in your instruction manual for more detailed information. Step 2.
Calibrating electronic level indicator Step 6. Switch off the agitation system. (This is to prevent movements in the tank when the tank is almost empty) Step 7. Open the main valve on the FMC control box. Step 8. Check if the liters on the ASV screen starts to run. Step 9.
Parameter and machine type information Because the iXclean Comfort box is used on different machines Parameter 26 (Machine type) This parameter is responsible for the flow schedule. the parameters are very important. This parameter is linked to the tank size. Below you see a parameter list of the ASV (IxcleanComfort) 0 = Ixter (<2000L) 1 = Trailed (>2000L)
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