Roberts Irrigation Company Inc. Service school 2014 Contact information P.O. Box 490 1500 Post Rd Plover, WI 54467 Robertsirrigationwi.com (715) 344-4747 fax (715) 344-4505 1-800-434-5224 In the north west contact Barry Graham (715) 296- 4211 It does not take very much current to cause serious injury or death. BE CAREFUL!!! 480 volt power if not properly used can kill you. Arc Flash is the result of a rapid release of energy due to an arcing fault between a phase bus bar and another phase bus bar, neutral or a ground. During an arc fault the air is the conductor. Arc faults are generally limited to systems where the bus voltage is in excess of 120 volts. Lower voltage levels normally will not sustain an arc. An arc fault is similar to the arc obtained during electric welding and the fault has to be manually started by something creating the path of conduction or a failure such as a breakdown in insulation. The cause of the short normally burns away during the initial flash and the arc fault is then sustained by the establishment of a highly-conductive plasma. The plasma will conduct as much energy as is available and is only limited by the impedance of the arc. This massive energy discharge burns the bus bars, vaporizing the copper and thus causing an explosive volumetric increase, the arc blast, conservatively estimated, as an expansion of 40,000 to 1. This fiery explosion devastates everything in its path, creating deadly shrapnel as it dissipates. The arc fault current is usually much less than the available bolted fault current and below the rating of circuit breakers. Unless these devices have been selected to handle the arc fault condition, they will not trip and the full force of an arc flash will occur. The electrical equation for energy is volts x current x time. The transition from arc fault to arc flash takes a finite time, increasing in intensity as the pressure wave develops. The challenge is to sense the arc fault current and shut off the voltage in a timely manner before it develops into a serious arc flash condition. When these pictures where taken this equipment was still very hot and smoking. This is why it is a good reason to make a walk around an piece of electrical equipment before using to insure no damage occurred since last use. Also check lightening arrestors. If it is not in one piece or has evidence of smoke coming out, it did it's job and needs to be replaced. The purpose of a lightening arrestor is to prevent power surges from damaging equipment. It does this by shorting the lines when the voltage reaches a certain point and ideally blowing a fuse. If the fuse is not blown it will continue to short until it self destructs. When this happens it can simply smoke up or dramatically explode. The Safety Alert Symbol is displayed many places throughout this manual and on your System to indicate when there is a potential for Personal injury. The movement of an Electrically Powered, Gear-Driven, Irrigation System is relatively slow. Moving parts are exposed and may present a potential hazard. Therefore, keep all equipment, vehicles, people, etc., out of the System’s path. DO NOT attempt to perform any maintenance procedures until the Reinke Main Control Panel Disconnect Switch and all Pump and other Disconnect Switches are locked in the “OFF” position. Electrical component trouble-shooting and replacement should be performed by a certified Reinke Service Technician to ensure built-in safety features remain intact. This also ensures System remains compliant with the National Electric Code and Reinke Manufacturing Specifications. Replace all Protective Guards and Shields before restoring power to the System. Do not allow anyone to ride or climb on the System unless they are qualified and required to do so for maintenance purposes. The Tower Steps have been provided for access to the Tower Control Boxes only. They are not intended for access to the Span. For instance, should the Sprinkler Heads require service, use a ladder to reach them from the ground. Exercise caution when handling fuel near Systems equipped with Combustion Engine-driven Generators and Pumps. If you suspect a short circuit or the System is not working correctly, do not touch the System and keep others away from it. Call Roberts Irrigation. Electrical component trouble-shooting and replacement should be performed by a certified Reinke Service Technician to ensure built-in safety features remain intact. This also ensures System remains compliant with the National Electric Code and Reinke Manufacturing Specifications. When towing a System from field to field, avoid ditches, rough terrain, overhead power lines, etc. The Ground Wire MUST be re-attached to the Ground Rod and checked for electrical integrity each time the System is towed. Avoid any bodily contact with high pressure water streams from Sprinklers and End Guns. Keep away from fields where the System is chemigating. Make sure the applied chemical and water does not blow or drift past the area of intended operation. A Check Valve must be installed between the Pivot Center and the Pump to prevent the mixture of water and chemical from siphoning back into the irrigation water source. Comply with all local, state, and federal regulations. Do not oversize Fuses. Fuses are sized for a specific circuit. It is very important to make sure you have the proper fuse size in place before initially starting the System and when replacing Fuses. Keep away from the System during thunderstorms or other severe weather conditions. The Center Pivot is grounded and the System is probably the highest object in the field, making it a good lightning receptor. Be sure Protective Guards are installed on all Belts and Driveshafts of Ancillary Equipment such as Combustion Engines, Electric Motors, Pumps, etc. Do not operate System when temperatures are below 40°F (4.5°C). This can cause structural damage to the System. In most states it is unlawful to spray water on state and county roadways. This is a serious hazard and must not be allowed. Driveshafts may start without warning. Keep away from Driveshafts to prevent clothing or limbs from being entangled, resulting in severe injury. . If your System is equipped with any AutoStop or Auto-Reverse Mechanism, make sure they are working correctly and a Tower Barricade is properly installed as per this manual. Reinke disclaims any and all liability (including any liability created pursuant to the Irrigation Systems Warranty) with regard to damage to the Irrigation System, or to other property, or personal injury or death, caused by improper installation or maintenance of Reinke-supplied Tower Auto-Reverse or Auto-Stop Switches or Tower Barricades, or by use of customer supplied Barricades Do not endanger your own life and possibly the lives of others by being Negligent. Maintain adequate crop clearance. Allowing the systems trussing to drag in the crop can cause structural damage to the system. New laws coming into effect April 1st The following are excerpts from a letter from the state. The full document can be found at http://dsps.wi.gov/Documents/Industry %20Services/Forms/Electrical/Electrical%20FAQ.pdf How to use a multimeter Safety Information A "Warning" statement identifies hazardous conditions and actions that could cause bodily harm or death. A "Caution" statement identifies conditions and actions that could damage the Meter or the equipment under test. To avoid possible electric shock or personal injury, follow these guidelines: • Use the Meter only as specified in this manual or the protection provided by the Meter might be impaired. • Do not use the Meter or test leads if they appear damaged, or if the Meter is not operating properly. • Always use proper terminals, switch position, and range for measurements. • Verify the Meter's operation by measuring a known voltage. If in doubt, have the Meter serviced. • Do not apply more than the rated voltage, as marked on Meter, between terminals or between any terminal and earth ground. • Use caution with voltages above 30 V ac rms, 42 V ac peak, or 60 V dc. These voltages pose a shock hazard. • Disconnect circuit power and discharge all high-voltage capacitors before testing resistance, continuity, diodes, or capacitance. • Do not use the Meter around explosive gas or vapor. • When using test leads or probes, keep your fingers behind the finger guards. • Only use test leads that have the same voltage, category, and amperage ratings as the meter and that have been approved by a safety agency. • Remove test leads from Meter before opening the battery door or Meter case. • Comply with local and national safety requirements when working in hazardous locations. • Use proper protective equipment, as required by local or national authorities when working in hazardous areas. • Avoid working alone. • Use only the replacement fuse specified or the protection may be impaired. • Check the test leads for continuity before use. Do not use if the readings are high or noisy. We will be discussing the Fluke 117 and recommend it as an very capable basic meter. It is available from many places and cost in the range of $155. Before doing any measurement you should check the quality of his test probes and leads for both physical wear and electrical fitness. To check electrically set the meter to ohm and hold both probes together. You should read near 2 ohms or less. If your leads do not read this or appear damaged REPLACE IMMEDIATELY. Most of the voltages that we will be testing will be AC or alternating current and is what the power company or your generator will supply. DC or direct current is generally was is coming from a battery. Even though the 117 can measure current it does not measure past 10 amps and must be put into the circuit. We recommend the use of a separate camp on meter or probe for current measurements They can be purchased for under $100 Even though the 117 can measure current it does not measure past 10 amps and must be put into the circuit. We recommend the use of a separate camp on meter or probe for current measurements They can be purchased for under $100 Terminology 1 Riser pipe 2 Top elbow 3 Pivot leg 4 Pivot bearing 5 Cam Plate or Wheel 6 Main control panel 7 Pivot Boot 8 Collector ring 9 Pivot gasket 10 Incoming power 11 Lower elbow 12 Pivot walk way Terminology 1 Tower top 2 Tower boot 3 Springs and spears 4 Tower box 5 Tower stiffener 6 Tower auto-stop/ auto reverse 7 Center Drive 8 Wheel gear 9 Flange 10 Hook joint Your tower auto stop or auto reverse should be checked yearly for operation. This will also test the safety circuit of the machine to insure there have been no compromises On the left is a helical center drive. It comes in several gear ratios including 25.5:1, 30:1, 40:1, 60:1. Also there is with and with out thermal protection. Corner arms do not have thermal protection on there center drives. The middle is an example of a worm gear. These come in several gear ratios also 21:1, 30:1, 40:1, and 60:1. On the right we have a rain resistant motor they come as 1 hp and 1.5 hp. Also with and with out thermal protection. When replacing any motor make sure that somewhere it has thermal protection on it. This is what is going to save the motor from burning up should something go wrong. That protection will be built into the motor like the new machines are or in the tower boxes like the old machines were. Terminology At the beginning we start with the pivot point. Then all A towers The next to last tower is the B tower The last tower is the C tower on a straight machine. Terminology End boom End gun Booster pump Terminology Control panel Standard Rpm Advanced / Pac 3 Rpm Preferred / Rams Rpm Preferred touch Why one panel vs. the other? Terminology Service is where your power comes in from the power company. Normally from there it goes to the pump panel/vfd Then off to the pivot. All panels and equipment should be checked at least yearly for holes, rust, or damage from rodents or people. Terminology Pump Panel / Well panel VFD Terminology Hinge tower Corner arm/sac Terminology Fuses These are the various fuses that may be in your pivots. To test a fuse remove it from the circuit when the power is off. Place your meter in ohms. Place one lead on each metal end of the fuse. A good fuse depending on the size and type will read less than 10 ohms. You can also place the meter in continuity and listen for the beep. Some fuses you can see are bad but do not count on that meaning they are good. Fuses can look good and still be bad. Checking a pressure switch can be difficult. It needs to have pressure to close. After getting it closed it is just like checking a fuse. We are looking for less than 5 ohms. It can also be tested based on how it works in the system. The Pac timer can be tested for timing accuracy with a stop watch. Overwatering timers should be checked every year. To do so start your system and turn it to 0% or speed off. In about 20 minutes or less your system should shut off. Percent timers should also be checked yearly. They would be tested with a stop watch. It times with a pecentage of a minute. At 50% it would be on for 30 seconds and off for 30 seconds. Micro-switches typically have 3 screws on them. There is a common or C, a normally open or N.O. And a normally closed or N.C. When the switch is not depressed is should read much like a fuse between C and N.C. When the switch is depress it should read between C and N.O. Disconnect It is just a special kind a switch. To test this with the power off measure from one side to the other side of the same “pole” or wire. It should measure less than 5 ohms. Contactors and relays are simply electrically actuated switches. There are 2 things to check on contactors and relays. The first being the coil. This is where power is applied to activate the switch. And the switch part it's self. The coil for the relay should be check for ohms against a known value specific to that relay. The contacts or switch part should either be open or closed similar to the micro-switch. An overload is a current measuring device designed to make sure a motor is not over worked. It needs to be set to the full load current of the motor it is being used on. It can be tested in 2 ways. The first is the control contacts or switch to make sure it is closed to allow operation. Second is through the measuring part of it to make sure that it is not affecting the motor it is working on. Coils for valves are just like the coils for a relay or contactor. They are measured against a known value to determine if they are good. The skinner coil used on many end guns should have an ohm reading of 180 Ohms ± 10%. Care must be taken when measuring any device that the power is off and that it is sufficiently removed from the circuit so it is not affected by the rest of the circuit. Arc suppressors These reduce the arcing that occurs when power is removed from a coil. They will increase the life of the switch controlling it. Whenever changing a contactor, relay, or coil with one on, or if it is physically damaged, replace the arc suppressor also. Here we have an example 2 of the more common end gun and 3 most common valves to control them. The Nelson SR 100 and komet twin 101 end guns. And the nelson 800 valve, 2” auquamatic, or komet 850 valve. Here is one example of a 2 horsepower booster pump. Currently they are mounted different but function the same. The Basic Pivot Color Code 1 2 3 4 5 6 7 8 9 10 Neutral Percent End gun Safety Ground Forward Reverse L1 L2 L3 White Orange Yellow Brown Green Purple Pink / Old systems gray Blue Red Black This is also the order a collector ring is typically wired. To test the collector ring with the power off test from the top wires to the bottom slip rings with a meter for low ohm (less than 5) or continuity. Make sure that when you do this you unhook one side to ensure you are not reading other circuits. Pivot stop switch Check every year that this switch works and is adjusted to hit the trip. To test go into the collector ring and read between the red and blue with an ohm meter. It should read less than 5 ohms without being tripped. And OL while tripped. This switch works by opening the safety circuit. We will discuss this in more detail later. The end gun switch This is used to automatically actuate the end gun on and off. To test measure between blue and red just like a stop switch. Care must be taken that the switch is rewired correctly the red wire must be wire nutted to the yellow wire and the blue wire is put into the slip ring. This is wired so that any induced voltage from the other wires in the span cable is removed when the circuit is off to ensure the end gun turns off. The switch should also be checked yearly for alignment and movement. If the switch does not spring into position it should be replaced Your pivot may not have either of these switches depending on the type of panel that you have. The A Box The A box is the most common box on the system, it consists of a disconnect, A contactor, 2 micro-switches, a set of cams and a yoke with thumb screws. If you have an older system it may also include overload protection. This box uses the alignment system to tell the tower that it is on when to start and stop. If the tower gets out of alignment it will shut the whole machine down. If the Disconnect in the tower box is off the machine will not stay running. The B Box The B box is just like the A box but it also has the over watering timer. This timer resets when the tower moves and counts down when the tower stands still. If it does not move in the allotted time the safety circuit will open up and shut the machine down. Typically this is 20 minutes. The C box The C box is the simplest box to start with but when wired gets more complex. It just has a disconnect and contactor to start with. This is because you add several things into it. For example you can have a booster pump, end gun solenoid, end run light, GPS, Tower auto stop, and auto reverse. This is where the safety gets hooked to neutral and sent back to the pivot panel. Booster pump box This box controls the booster pump if it is equipped. It consists of a disconnect, a honeywell relay, pressure switch (depending on age), and a reversing contactor. The purpose of the reversing contactor is to provide power to the pump so that is only spins in one direction no matter which way the system is going. We will go into detail of this later. The honeywell is there to allow the reversing contactor to operate properly. Every booster pump should have a working pressure switch so that it will not run with out water. If it does this will greatly decrease the life of the pump. Main Control panel Main disconnect This is where our 3 phase 480 comes in and where our first set of fuses are. With this off there should not be power anywhere else in the panel. Caution: Not all applications are the same, voltage may be present. After the power leaves here one place it will go is to the transformer. This steps down the voltage from 480 to 120 volts. There are 3 fuses here and must be removed to be tested. Our control circuits are powered with 120 volts. The 3 phase power also will go to the main reversing contactor. There are 2 contactors joined together in a way that only one is able to pull in at a time. This is what switches direction for the machine. It does this by swapping 2 of the 3 phase wires depending on direction. A pivot will run clockwise in forward and counter clockwise in reverse. If it is trying to go in reverse when it is suppose to be going forward it is out of phase. A pivot needs to have the phasing checked whenever it has a new power source applied to it. To change and out of phase system to be in phase it is recommended to swap L1 and L3, or the out side 2 wires after the power has been turned off. ALWAYS check to make sure the power is off before working on any equipment. The other part of the Reversing contactor is done by the auxiliary contacts. These contacts send 120 volts down the forward and reverse wires, depending on direction, to tell the towers which way the system is running. They also provide us with a source of power. This will be explained in more detail later. When the pivot is to run forward, the forward contactor's coil gets powered and pulls in. The same happens with in reverse. When the system is started these contactors are what you hear “pull in.” If the machine does not stay running on it's own you will hear them “drop out.” Another part of the reversing contactor involves the safety circuit. The control of that comes from our safety relay. When the start button is pushed you are overriding the machine's safety circuit. If the safety is good the safety relay will “pull in” and “latch” the main reversing contactor. Next lets look at the safety circuit. On our straight Reinke machine we have a “cold” safety. This means that when safety is good we bring back a neutral to the main control panel. This safety starts at the C box and goes through things like tower auto stops, tower auto reverse, tower box disconnects, safety micro switches, and pivot stop switches for example. Any one of these items can open safety and stop the machine. Safety should be check with the power off by reading a continuity loop with an ohm meter between safety and neutral, Brown and white, any where on the system out to the end. Be sure to isolate out that part of the circuit when doing so. You should have a reading of less than 15 ohms when good. If our safety in our machine is good it will “pull in” the safety honeywell relay. One side of this relay is powered with 120 volts. If the safety is open and the main disconnect is on there will be 120 volts on the safety circuit and the pivot side of the open. This is one more reason to test with the disconnect off. The coil of this relay should read 280 ohms. With our safety relay “pulled in” and power to the coil of one of our reversing contactors there is a circuit and our contactor “pulls in” and allows our machine to start running. This also provides 120 volts to some other circuits in our panel. One of the things that gets power is the percentage timer. This is what normally powers the 2 lights and the end tower contactor to make the end tower run. 120 volts is applied to the “motor” and as time goes by it opens and closes the contacts a percentage of 60 seconds. The signal of 120 volts is sent out on the orange wire when ever the end tower is suppose to be moving. This also lights up the running lights at the same time. The next circuit is the end gun and water supply circuit. When the water supply switch is turned on and the machine is running 120 volts is sent out on the yellow wire. Also the “well control” honeywell is energized and closed. This will send out the signal necessary for your pump to turn on and or stay running. The yellow wire is then closed or broken by the end gun switch and sent out to the end tower. This is where it is connected to the skinner coil or the booster pump box. If it is a skinner coil it can be tested from the pivot with an ohm reading. Switch on it should read around 190 ohms. This varies based on machine. Now that we have the basic system down lets move onto some options. Rpm Adv Most of our system and even pivot panel stays the same. However we remove the 2 switches at the pivot point. And the “face plate” changes. There are 2 fuses to check on this timer. They are different, one is ¼ amp and the top board is a 4 amp. RPM Preferred / RAMS There are 3 fuses to be check and changed on the back of here. They are a value of AGC 2.5. This is similar to the Adv. Panel as far as the rest of the system is wired. Rpm Touch There are 3 fuses here also they are all MDL and value of 1.5 and 4 amps. Caution needs to be taken when removing the fuse so the circuit board it is mounted on is not damaged. The wireing is also similar to the Pac 3 and Rams on the rest of the system Cold wire GPS This is the current end of system gps. This is what gives our computerized pivot panel it's location information. When your screen displays satellites this is where that information is coming from. There are 2 wires for data and 3 wires for power. That power is coming from forward or reverse and neutral. On the next slide we will see how it is wired into the end. Trouble shooting End of system GPS For the old style end of system GPS, hot wire GPS, we are going to watch the lights and see how they are blinking. No power light on- Check incoming power to Line Receiver. If you have power then the receiver is bad Unless the lights are blinking they have no meaning. Line data blinks when ever we receive data from the end tower. Data out blinks when ever we send data to our computerized panel Error blinks if the data coming from the end is bad. Both GPS units take time to acquire satellites to run. This can be several seconds to several minutes. This is normal. When you see a STALL error on your panel or FRCD DR this means that you are not receiving GPS data. With a STALL the machine has shut down. Forced Dead reckoning it is still operating and guessing where is should be for a short time until the GPS updates or it turns into a Stall. This is one version of the old style end of system board or Hot wire. The power light indicates we have power. The base light indicates the board is put into a base recording mode. The WAAS light indicates whether or not we are using the more accurate WAAS satellites. The Sats >3 light indicates when our satellite count has gone above 3 The Data out light indicates we are sending data to the pivot The GPS data light indicates that we are getting data from our anttenna. If you do not have GPS then you will have a resolver in the collector ring for positioning data. There are 2 data wires and 2 power wires. There is also a fuse in this box ¼ amp AGC. Operation Trouble shooting Alignment Keep in mind that do to normal wear to the structure of the machine alignment will have to be adjusted. A machine can continue to run very crooked for a very long time if the alignment is not properly set. This however causes stress to the machine if it is left for too long and too severe. If your pump won't start double check that the power company does not have you on control for those of you that are under this program. Preseason Maintenance Warranty for retro or replacement parts Wheel gears Center Drives Electrical 5 years 2 years 2 years When picking up a replacement parts we may need information to activate the new parts warranty. This includes the parts serial number, the system serial number, system hours, old part serial number, and field name. If in the first 10 years the gear oil is replaced with sprinkler lube it can be extended another 2 years and 2000 hours. It is recommended this be done after the first 2 years A basic E2 span can weigh up to 4000 lbs empty, use adequate lifting equipment when changing any wheel gears or tires. Before starting your turbine pump it is our recommendation to let 1 gallon of mineral oil drip down to prelubricate the pump. Then throughout the season make sure your dripper is adequately filled with mineral oil. If you have a centrifugal pump make sure your packing gland is properly adjusted. Keep in mind if a vertical hollow shaft motor is to be moved the oil must be removed to retain warranty. GE motor Baldor motors used on centrifugal pumps and some rotary phase converters There is also a grease zerk on the under side of the newer collector reels. The first time the machine is to be run you should check the operation of your sprinklers and pressure regulators if equipped. With the regulators it is important to make sure water is not spraying out of the seems. Also compare operating pressure to what your system is suppose to be at. If it is too low it can indicate that there is a problem with the water supply. Maintenance in season If regular inspection of sand pumping is not kept up this could happen to you. If possible it is recommended to shut off as many disconnects as possible( service, pump, and pivot). This will isolate out each part in case there is a lightning strike or power surge. This is especially true if a storm is approaching. Post season Maintenance It is also recommend to lock equipment off if not in use when there is concern about vandalism. If you are going to leave it powered up be sure to pull the control fuses on the well so that it can not be accidentally started after the underground lines have been pumped out. Recommended replacement parts to have on hand 1 set of fuses for all equipment, this includes the service, pump panel, pivot panel, and computerized panel Pivot light bulbs Optional replacement parts to have on hand Tower contactor, microswitch, arc suppressor, and skinner valve RPM Advanced / PAC 3 timers The original PAC 1 timer was designed to improve on the mechanical % timers. It had a simple design 2 dials to set the depth of application, one for each direction. The PAC 2 timer looks very similar to the current PAC 3 timer. It has 4 buttons and a settings menu. These timers can be simple percent timers or upgraded to include Parks, 2 end guns, and sector programing. The PAC 3 timer is the current model. It can be used in 3 levels of operation. The first being a basic percentage timer. The next level adds a park, end gun, and sector programing capability. This is the PAC 2 end gun option. The highest level is the RPM advanced add on board. This option gives you park, end gun, sector, pressure override and restart, auto reverse, and remote control capabilities. Running a pivot with a PAC 3 timer is very similar to a basic percentage timer. The main differences start with setting the speed. You are no longer determining a percentage of speed but a depth of application. The next difference comes when you have the upgraded timers. Your end guns, and park or pivot stop are not set in the timer. The last major difference occurs with the RPM ADV, if set to it can override the low pressure safety when ever the machine is started automatically for a predetermined time. If your pivot does not try to pull in the main contactor check this setting. You can verify what it is suppose to be based on the board mounted on top of the PAC timer to the right.