giltrap generation ii rf control system...rf gen ii system technical manual rev02_12_10.doc 2...

GILTRAP GENERATION IIRF CONTROL SYSTEM

Operating, Installation & Technical Manual

February 2010

Introduction..................................................................................................................................................... 2Control Mode Options .................................................................................................................................... 2Remote Display Layout ................................................................................................................................... 3Controller Layout............................................................................................................................................ 3

Operation Section..........................................................................................................4Overview ......................................................................................................................................................... 4Valve Over-ride Function ............................................................................................................................... 4

REMOTE DISPLAY SCREENS ................................................................................................................................. 5Screen Symbols ............................................................................................................................................... 5Start-up Screen................................................................................................................................................ 5Standard Mode Screen .................................................................................................................................... 6Weight Mode Screen ....................................................................................................................................... 7Distance Mode Screen..................................................................................................................................... 8Speed Mode Screen ......................................................................................................................................... 9Scales Screen................................................................................................................................................. 10

Installation Section......................................................................................................11Component Layout ........................................................................................................................................ 11Remote Display Mounting & Power Supply.................................................................................................. 12Forage Wagon Controller & Power Supply.................................................................................................. 12Setting the RFID Number.............................................................................................................................. 14Fitting the Power Module Circuit Board ...................................................................................................... 15Fitting the Wheel Sensor ............................................................................................................................... 15Fitting the Load Cells ................................................................................................................................... 16Setting System Parameters............................................................................................................................ 17Checking Setup Parameters .......................................................................................................................... 21Factory Parameter Settings .......................................................................................................................... 22Final Check................................................................................................................................................... 23

Technical Section ........................................................................................................24Power and Charging..................................................................................................................................... 24System Display LEDs .................................................................................................................................... 25System Safety Fuses ...................................................................................................................................... 26Radio Frequency Device ............................................................................................................................... 26Wiring Schematic .......................................................................................................................................... 27Cable Descriptions........................................................................................................................................ 29Remote Display Screen Contrast................................................................................................................... 30Fault Diagnosis............................................................................................................................................. 31

Generation II RF Control System – Operating, Installation & Technical Manual

RF Gen II System Technical Manual Rev02_12_10.doc

2

Introduction

The Giltrap Generation II RF Control System consists of a Controller that is mounted on thewagon that uses wireless technology to relay data such as feed rate, load weights or feed-out amounts (depending on options purchased) from the wagon and displays it on theRemote Display mounted near the operator on the tractor, allowing the operator to controlthe feed rate using different modes.

Powerfully capable, yet simple to use, the controller has large buttons and an easy-to-readdisplay allowing the operator to constantly monitor, and adjust the feed rate when needed, allwhile on the move.

Control Mode Options

The system has a total of five different operation modes available. The availability of theseare dependant on the hardware options fitted to the machine.

Hardware available: Load cells – for weight readingsSolenoid coil – for floor controlWheel sensor – for ground speed calculation

Standard ModeThe operator controls the feed rate through a percentage range from 0 to 100%.Requires a solenoid coil to be fitted. Load cells are optional.

Weight ModeThe operator can enter a target weight to feed. The feed rate control is the same as Standardmode.Requires load cells and solenoid coil to be fitted.

Distance Mode (also known as Fully Automatic mode)The wagon will unload the required amount over the required distance, and will compensatefor changes in ground speed.Requires load cells, solenoid coil and wheel sensor to be fitted.

Speed ModeThe operator controls the feed out rate through a percentage range from 0 to 100% and thefeed rate is automatically adjusted according to ground speed.Requires a solenoid coil and wheel sensor to be fitted. Load cells are optional.

Scales ModeOnly has a weight display. Requires load cells to be fitted.Floor rate is controlled manually.



3

Display screen

UP button

GO button

STOP button

RIGHT button

MODE button

DOWN button

Power plug

Power switch

TARE/GROSS button

LEFT button

ZERO button

Power light

Signal light

Signal light

Valve light

Weight connectionValve connectionPower connection

Power ONbutton

Power OFFbutton

Remote Display Layout

Controller Layout



4

IMPORTANTManual over-ride located beneath this

cover

To operate in case of electronicmalfunction, undo locking ring and

screw in adjuster.

Use ¼ - ½ turn adjustments.

Operation Section

Overview

Assuming installation (page 11 – 23) has been completed, the power for the system iscontrolled by the switch adjacent to the Remote Display.

1. Turn the switch on to provide power to the Remote Display and the wagon.

2. If the wagon is disconnected, press and hold the ON button on the Controller for onesecond. The Controller is now operating on its own battery.

3. Begin loading the wagon. See more detailed information regarding modes andbuttons.

4. Once completed loading, connect the wagon to the tractor and connect the 7-pinplug.

5. Once ready to feed, select the appropriate mode and press GO button. You are nowready to proceed.

Note: The Controller power light will illuminate when the ON button is pressed or the wagonis plugged into the tractor. To turn off, the wagon must be un-plugged before pressing theOFF button.

Valve Over-ride Function

When a solenoid is fitted for floor control, a manual over-ride function will also be provided.

Note: This function over-rides all RF floor rate control.

Use ¼ - ½ turn adjustments per time. Do not over-adjust.For electronic operation with RF control, the screw adjuster must be unscrewed all the wayout (anti-clockwise) and the locking ring tightened.

Locking ring

Over-ride adjuster

Label on cover



5

Remote Display Screens

Screen SymbolsApart from usual text characters, the screen can display other symbols at various times.

Start-up ScreenWhen the Remote Display is powered up, the start-up screen is displayed for 3 seconds asbelow. After this the screen will change to the operating screen.

If the wagon is not connected i.e. not getting power from the tractor, the controller will notstart. The screen below will display until communication has begun by plugging in the wagonor pressing and holding the GO button on the controller for 1 or more seconds.After establishing communication, it will proceed directly to the next screen.

Once communication has begun between the devices, a screen similar to the one below willshow.

The modes that are available are dependant on the hardware options fitted to the machine.

The battery symbol indicates when the system is operating on its own battery. Thevoltage display indicates the condition of the battery.

The antenna symbol indicates when the Controller and Remote Display havecommunication between them. This must show at all times for successful operation.

GILTRAP GEN IICONTROL SYSTEM

Channel: 1 Rev3.4

Remote Display softwarerevision

Remote Display RFchannel

FEED RATE: 50%DISPENSED: 0kgGROSS: 2950kgSTOP Std 12.5V

Waiting forRF Forage WagonCommunications...



6

Standard Mode ScreenIn standard mode, the feed rate is shown as a percentage. A range of 1-100% is availablewith 100% being maximum feed rate. This rate is shown on the top line of the screen. Thismode is useful for general operation and is the most simple to use.

Screen Features: The top line shows the feed rate.

The bottom line of the screen shows the status of the system (STOP), the mode of operation (Std)and connectivity status.

Additional features that show if load cells are fitted: The second line will show the weight dispensed since GO was pressed.

The third line will display the present wagon weight. This may be gross or tare.

The bottom line of the screen shows the status of the system (STOP), the mode of operation(Std), the battery voltage (highest voltage available to the unit. When disconnected from thetractor, this will be the internal battery voltage), and connectivity status.

Operating Notes:

Screen Warnings:

“WAGON POWER NOT CONNECTED” will flash on the display if the GO button on the RemoteDisplay is pressed without the wagon being plugged into the tractor and/or power not getting fromthe tractor to the Controller.

FEED RATE: 50%DISPENSED: 1050kgGROSS: 2950kgSTOP Std 12.5V

FEED RATE: 50%

STOP Std

Rate control only

Rate control withload cells fitted

Feed Rate

System status

Mode of operation

Connectivity status

Dispensed amount

Product amount in machine

Battery voltage

System battery indicator

The operator can adjust the rate percentage figure by pressing UP orDOWN on the keypad.

The operator can select between gross and tare weight to bedisplayed by pressing TARE/GROSS on the keypad.

The operator can zero only the dispensed weight by pressing GO onthe keypad.

The operator can start and stop the feed-out by pressing GO andSTOP on the keypad.

The operator can switch to other available operating modes bypressing MODE on the keypad.

The operator can zero the gross and dispensed weight by pressingZERO on the keypad.



7

Weight Mode Screen

In Weight mode, the feed rate is shown as a percentage. A range of 1-100% is availablewith 100% being maximum feed rate. This rate is shown on the top line of the screen.The operator can enter a target weight to feed out before the wagon floor will stop movingand the system status will return to STOP.(V3.9 onwards) The operator can enter a target weight to feed out before a beeper willsound and the wagon floor will stop moving and the system status will return to STOP.(All) The TO FEED value must be greater than zero else the system will not operate. UseSTANDARD mode for feeding if weight quantities are required.

Screen Features:

The top line shows the feed-out rate. The second line shows the weight to feed out before a beeper sounds. The third line shows the weight of the current load. This may be gross or tare. The bottom line of the screen shows the status of the system (STOP), the mode of operation

(Weight), the battery voltage (highest voltage available to the unit. When disconnected from thetractor, this will be the internal battery voltage), and connectivity status.

Operating Notes:

Screen Warnings:

“WAGON POWER NOT CONNECTED” will flash on the display if the GO button on the RemoteDisplay is pressed without the wagon being plugged into the tractor and/or power not getting fromthe tractor to the Controller.

FEED RATE: 50%TO FEED: 560kgGROSS: 2950kgSTOP Weight 12.5V

Mode of operationSystem statusSystem battery indicator

Feed Rate

Target weight to feed

Product weight in machine

Connectivity status

Battery voltage

The operator can alter the feed-out rate by adjusting the ratepercentage by pressing UP or DOWN on the keypad.

The operator can adjust the weight to be dispensed by adjusting the‘TO FEED’ figure. This is done by pressing UP or DOWN on thekeypad when the ‘TO FEED’ figure is underlined. Use the RIGHTor LEFT button to move the underline cursor.

The operator can start and stop the feed-out by pressing GOand STOP on the keypad.

The operator can switch to other available operating modesby pressing MODE on the keypad.


The operator can zero the gross and dispensed weight bypressing ZERO on the keypad.



8

Distance Mode Screen

In Distance mode, the feed rate is automatically set by dispensing feed over a set distance.

Screen Features: The top line shows the weight to feed out. The second line shows the distance over which to feed this weight. The third line shows the present wagon weight. This may be gross or tare. The bottom line of the screen shows the status of the system (STOP), the mode of operation (Dist), the

battery voltage (highest voltage available to the unit. When disconnected from the tractor, this will be theinternal battery voltage), and connectivity status.

Operating Notes:

Screen Warnings: “WAGON POWER NOT CONNECTED” will flash on the display if the GO button on the Remote Display is

pressed without the wagon being plugged into the tractor and/or power not getting from the tractor to theController.

“INCREASE GROUND SPEED” will flash on the display when the wagon is travelling too slow and causingthe machine to overfeed. Note that ground speed needs to increase not tractor revs.

“DECREASE GROUND SPEED” will flash on the display when the wagon is travelling faster than themachine can feed. Note that ground speed needs to decrease not tractor revs.

TO FEED: 1800kgLENGTH: 100mGROSS: 2950kgSTOP Dist 12.5V

Mode of operation

System status

Feed to dispense

Distance to travel


Connectivity status

Battery voltage


The operator can adjust the weight to be dispensed by adjusting the‘TO FEED’ figure. This is done by pressing UP or DOWN on thekeypad when the ‘TO FEED’ figure is underlined. Use the RIGHT orLEFT button to move the underline cursor.

The operator can adjust the distance to feed the weight over byadjusting the ‘LENGTH’ figure. This is done by pressing UP or DOWNon the keypad when the ‘LENGTH’ figure is underlined. Use theRIGHT or LEFT button to move the underline cursor.

The operator can start or stop the operation by pressing GO or STOPon the keypad. If the feed bins are unequal in length, enter the totallength of the bins in the ‘LENGTH’ figure and the total amount to feedin the ‘TO FEED’ figure. After travelling the first bin, press STOP on thekeypad. The display will change from RUN to WAIT. You can thentravel forward or backward without the distance changing. Press GO tocontinue or press and hold the STOP button for 3 or more seconds toreset the system status to STOP. The system will automatically returnto STOP mode after counting down the distance to zero.

The operator can switch to other available operating modes bypressing MODE on the keypad.

The operator can select between gross and tare weight to be displayedby pressing TARE/GROSS on the keypad.

The operator can zero the gross and dispensed weight by pressingZERO on the keypad.



9

Speed Mode Screen

In Speed mode, the machine will maintain a consistent feed-rate relative to ground speed.The feed rate percentage is adjustable from 1 – 100%.

Screen Features: The top line shows the feed rate. The bottom line of the screen shows the status of the system (STOP), the mode of operation

(Speed) and connectivity status.

Additional features that show if load cells are fitted: The second line shows the weight fed out since the wagon was loaded. The third line shows the present wagon weight. This may be gross or tare. The bottom line of the screen shows the status of the system (STOP), the mode of operation

(Speed), the battery voltage (highest voltage available to the unit. When disconnected from thetractor, this will be the internal battery voltage), and connectivity status.

Operating Notes:

Screen Warnings: “WAGON POWER NOT CONNECTED” will display if the GO button on the Remote Display is

pressed without the wagon being plugged into the tractor and/or power not getting from the tractorto the Controller.

FEED RATE: 50%

STOP Speed

FEED RATE: 50%DISPENSED: 940kgGROSS: 3540kgSTOP Speed 12.5V

Rate control only

Rate control andload cells fitted

Feed Rate

System status

Mode of operation

Connectivity status

Dispensed amount


Battery voltage


The operator can alter the feed-out rate by adjusting the rate percentage bypressing UP or DOWN on the keypad while in STOP mode only.

The operator can adjust the weight to be dispensed by adjusting the ‘TOFEED’ figure. This is done by pressing UP or DOWN on the keypad whenthe ‘TO FEED’ figure is underlined. Use the RIGHT or LEFT button to movethe underline cursor.

The operator can start or stop the feed-out by pressing GO or STOP on thekeypad.

The operator can zero only the dispensed weight by pressing GO on thekeypad.

The operator can switch to other available operating modes by pressingMODE on the keypad.

The operator can select between gross and tare weight to be displayed bypressing TARE/GROSS on the keypad.

The operator can zero the gross and dispensed weight by pressing ZEROon the keypad.



10

Scales Screen

In Scales mode, the screen will only display weight figures. This mode is used when no ratecontrol is fitted to the wagon.No other modes are available if only load cells are fitted.The operator can enter a target weight to feed when a beeper will sound, the wagon floor willstop moving (if the floor control solenoid is fitted) and the system status will return to STOP.

Features:

The top line shows the weight to feed out before a beeper sounds.

The second line shows the weight dispensed since GO was pressed.

The third line shows the tare or gross weight in the machine.

The bottom line of the screen shows the mode of operation (Scales), the battery voltage (highestvoltage available to the unit. When disconnected from the tractor, this will be the internal batteryvoltage), and connectivity status.

Operating Notes:

Screen Warnings:

None

TO FEED: 560kgDISPENSED: 733kgGROSS: 3440kgSTOP Scales 12.5V

Mode of operation

System status

Target weight to feed

Dispensed amount

Amount in machine

Connectivity status

Battery voltage


The operator can adjust the weight to be dispensed by adjusting the‘TO FEED’ figure. This is done by pressing UP or DOWN on thekeypad when the ‘TO FEED’ figure is underlined. Use the RIGHT orLEFT button to move the underline cursor.


The operator can zero only the dispensed weight by pressingGO on the keypad.

To allow the dispensed weight to accumulate and the targetfeed weight to work, the operator must press GO beforecommencing feeding.

The operator can zero the gross weight and dispensed weightby pressing ZERO on the keypad.



11

Installation Section

Component Layout

Valve cable#TCS-V2CABVAL

Data cable (1m) #TCS-V2CABWGT

Wheel sensor (5m)#TCS-OEM-PROX

Load cells (4 or 6)#ES-WLY00003P

Weight module#TCS-V2WGTMOD

Remote display#TCS-V2DISP

Valve assembly#HYSUPERVC-DPBM

Power module#TCS-V2PB

Cable from switch to tractor plug (2m)

Controller power cable (1m)#TCS-V2CABCON

Battery#TCS-BATTERY2

7 core cable (5.5m) with plug#TCS-LOOM2

Cab switch

12 – 24VDC Supply(Tractor battery)Brown - PositiveBlue - Negative

5A Fuse

Battery cable (0.55m)#TCS-V2CABBAT

Controller#TCS-V2CONTR

Cable from battery to switch (5m)

5A Fuse

Tail lights

7 pin plug#PLUG7PINM

Install loom #TCS-LOOM1 (with box)Install loom #TCS-LOOM1V2 (no box)

#LIGHTLED-LH #LIGHTLED-RH

Remote display cable#TCS CABLE



12

Remote Display Mounting & Power SupplyThe Remote Display is designed to be mounted in the tractor cab and be easily accessible tothe driver. It contains a radio frequency (RF) communication device to control the ForageWagon Controller (Controller).It will require shielding from the weather elements of sun and rain etc.

The Remote Display requires 12-24 volts DC to operate. It will typically only draw 0.2A. Thepower supply must originate from the tractor battery as part of the installation loom (suppliedwith the machine).

Forage Wagon Controller & Power Supply

The Forage Wagon Controller is powered from the tractor while operating. Whendisconnected from the tractor, it draws power from its own sealed lead acid battery.

No installation wiring is required on the Forage Wagon.

The tractor requires an installation loom (supplied) which provides a switched and fusedpositive and negative supply from the tractor battery to the rear 7-pin socket. The tractorbattery is the best power supply point as it provides the most stable and “quiet” powersource. Do not use any other power source.

Tractor Plug

There are three CPC connectors on the Controller module.If a connector is not used, place the terminal cap over it.

RF positive supply fromwiring loom (BROWN)

RF negative supply fromwiring loom (BLUE)

Terminal cap

Wagon plug:

RF positive supply(BLACK) wire to be inpin 2

RF negative supply(BLUE) wire to becombined with (WHITE)wire into pin 3



13

Mounting the Modules

Modules should be mounted as illustrated.

Power wires should be kept separate where possible from the load cell cables. Only 2 screws are required at opposite corners of each module. Keep all cables clear of moving parts.

Control Module

Control Module mounting bracket

BatteryWeight Module

Power Module

Battery base plate

Run powercables thisside

Run load cellcables thisside



14

DIP switches

*** SETUP ***RFID Number1.00

Setting the RFID Number

The RFID Number setup screen is used to assign a wireless address to the Controller. Thisfeature is available to prevent interference between two systems when they are operated inclose proximity to each other.

To access the Remote Display RFID screen, re-power the display and press and hold theMODE button until a setup screen appears.

The operator can press the UP button or the DOWN button to adjust this value. Press GO toenter then STOP to escape. Re-power the Remote Display to access the new channel.

Controller Settings

After removing the Controller cover, a DIP switch with 8 white switches is visible.

The D.I.P. (dual inline plastic) switches which are labelled 1 to 8 are used to selectthe RF channel ID.

The switch is considered to be ‘on’ when switched to the right hand side.

The channel ID of the Controller MUST match the software setting of the RemoteDisplay.

If the channel ID is changed in either the Remote Display or Controller then you mustre-power both devices for the new setting to take effect. To re-power the Controller,unplug the POWER cable for 5 seconds.

The DIP switch settings are shown in the following table.

RFID # 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

SwitchOn N

one 1 2 1 3 1 2 1 4 1 1 1 3 1 2

2 3 3 2 4 2 2 4 3 33 4 4 4



15

Fitting the Power Module Circuit Board

The power board will need to be fitted if load cells are fitted. It is fitted into the power module.

Open the Power Module lid. Remove the wire joining block. Fit the circuit board with the supplied screws. Attach the wires as noted on the board.

Remove white wire from Power Module to control module cable and install Red, Green andBlue wires into Power Module circuit Board.

Fitting the Wheel Sensor

The wheel (proximity) sensor has to be adjusted halfway between the range of beingalways on and always off. This is approximately 5mm between the end of the sensor andthe wheel plate.

Take care when running the cable that there is enough slack to allow the axle to fullyoscillate.

Approx. 5mm



16

Recommended Load Cell Bolt Torque SettingsM20 - 280 ft/lbs or 380NmM24 - 490 ft/lbs or 660Nm

Fitting the Load Cells

Fit the studs to the load cell first before fitting the load cells to the machine using the boltsprovided.

Lower the top half of the wagon onto the studs. Tighten the top nut then back off ½ turn. Route the wiring through the pipe/brackets provided through to the junction box taking

care to keep the wiring tidy and away from moving objects.

Note: If installing PT brand load cells, there will be two extra blue and brownwires. Connect the Sense +ve (brown) together with Excitation +ve (red) andSense –ve (blue) together with Excitation –ve (black).

Weight Module Connection

When fitting load cells or a wheel sensor, see below for fitting information about connectingwires into the weight module.

Concave washer

Convex washer

Load cell

Stud and nut

Insert screw driver for top layer here

Top layer

Insert screw driver for bottom layer here

Bottom layer



17

*** SETUP ***Scale Damping Value1.00RANGE: 1-15

*** SETUP ***Load Cell Type5000.00kgRANGE: 5000-10000

*** SETUP ***Number of LoadCells4.00RANGE: 0-6

*** SETUP ***Load Cell Sens.2.00mV/VRANGE: 0-10

Setting System Parameters

Parameters are required to be set for the machine to function correctly.

Entering Configuration Screens To enter set-up, press TARE/GROSS and ZERO together for 4 seconds or until the

set-up screen appears. Press UP or DOWN to adjust the parameter. Press MODE to move to the next configuration screen. It will save what is displayed

on the screen. Press STOP to exit the configuration screens.

Scale Damping ValueThe “Scale Damping Value” parameter is a weightingvalue over which the weight is averaged. A highervalue will display a smoother weight display but won’treact to weight changes as quickly.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.

Load Cell TypeThe “Load Cell Type” parameter specifies themaximum load for each individual load cell used on thewagon.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.

Number of Load CellsThe “Number of Load Cells” parameter specifies thetotal amount of load cells fitted to the machine. Enter 0if no load cells are fitted.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.

Load Cell SensitivityThe “Load Cell Sens.” parameter specifies sensitivity ofthe load cells used on the wagon. The setting is in mVper Volt. This means mV output per Volt of excitation.This is a characteristic of the load cells used.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.



18

*** SETUP ***Scale Hysteresis10.00kgRANGE: 1-200

*** SETUP ***Scale Increments10.00kgRANGE: 1-200

*** SETUP ***Wheel Diameter760.00mmRANGE: 0-1400

*** SETUP ***No. of Wheel Holes15.00RANGE: 0-50

*** SETUP ***Max Valve PSI2100.00psiRANGE: 0-3000

*** SETUP ***Wheel Sensor FittedYESRANGE: 0-1

Scale HysteresisThe “Scale Hysteresis” parameter specifies how mucha weight reading needs to change before the readingon the screen will change.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.

Scale IncrementsThe “Scale Increments” parameter specifies minimumscale increment displayed on the screen.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.

Maximum Valve PressureThe ‘Max Valve PSI’ parameter sets the elevator loadsensing pressure. Reduce this value if the elevatorstalls too often. Ideally this should be setapproximately 200 – 300 PSI below tractor reliefpressure.The operator can press UP or DOWN to adjust this value. Press MODE to continue.

Wheel Sensor FittedThe ‘Wheel Sensor Fitted’ parameter indicates if thewheel sensor is fitted or not and displays appropriatemodes to suit.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.

Wheel DiameterThe “Wheel Diameter” parameter is used to calibratethe wheel size on the machine.The operator can press UP or DOWN to adjust thisvalue. Note: For accuracy, measure from the ground tothe centre of the hub (and double) when the machine ishalf loaded. This will compensate for tyre pressure.Press MODE to continue.

Number of Wheel HolesThe “Number of Wheel Holes” parameter is used tocalibrate the distance measurement for the number ofholes on the encoder disk used by the speed sensor.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.



19

*** SETUP ***Low Batt Level11.50VRANGE: 0-30

*** SETUP ***Valve FittedYESRANGE: 0-1

*** SETUP ***Min Valve Setting30.00RANGE: 0-100

*** SETUP ***Valve Ramp Up Time0.00secRANGE: 0-10

*** SETUP ***Valve Startup Dist.85.00%RANGE: 0-100

*** SETUP ***Valve Ramp Up Time0.00secRANGE: 0-10

Low Battery LevelThe "Low Batt Level" parameter defines the minimumbattery voltage level at which the screen will switchfrom displaying voltage to displaying “LOBAT”. Thisfunction can be cancelled by setting the voltage to0.00V.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.

Solenoid Valve FittedThe ‘Valve Fitted’ parameter indicates if the solenoidvalve is fitted or not and displays appropriate modes tosuit.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.

Minimum Valve SettingThe "Min Valve Setting" parameter defines theminimum valve opening percentage when in Distanceand Speed mode, while running. When stopped, thevalve will go to 0.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.

Valve Ramp Up TimeThe ‘Valve Ramp Up Time’ parameter changes thevalve ramp up time.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.

Valve Ramp Down TimeThe ‘Valve Ramp Down Time’ parameter changes thevalve ramp down time.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.

Valve Start-up for Distance SettingThe “Valve Startup Dist.” parameter is the initial valvesetting to use when the machine is started in Distancemode.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.



20

*** SETUP ***Speed Mode MaxSpeed10.00km/hRANGE: 1-20

*** SETUP ***Speed Mode MinSpeed1.00km/hRANGE: 0-5

*** SETUP ***Speed Mode Strt.Time1.00secRANGE: 0-20

*** SETUP ***Dist. Before Finish1.00mRANGE: 0-10

*** SETUP ***Shut Down Timer20.00minRANGE: 1-60

Minimum Speed while in Speed ModeThe "Speed Mode Min Speed" parameter is only usedfor Speed mode. It defines the minimum speed themachine must be moving before the machine begins tooperate. This function is adjustable between 0 and 5km/h, with increments of 0.1km/h.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.

Maximum Speed while in Speed ModeThe "Speed Mode Max Speed" parameter is only usedwhile in Speed mode. It defines the theoreticalmaximum speed the machine will reach at which pointthe machine will be operating at maximum feed rate.The lower this is set, the more aggressive the machinewill operate. This function is adjustable between 1 and20 km/h with increments of 1km/h.Any speed over this parameter will cause the machine to run at the percentage setting on thedisplay.The operator can press UP or DOWN to adjust this value. Press MODE to continue.

Speed Mode Start-up TimeThe "Speed Mode Strt. Time" parameter is only usedwhile in Speed mode. It defines the length of time themachine must be moving above the minimum speedbefore it begins its usual function. This function isadjustable between 1 and 20 seconds with incrementsof 1 second.The operator can press UP or DOWN to adjust this value. Press MODE to continue.

Distance before FinishThe "Dist. Before Finish" parameter is only used whilein Distance mode. It defines the length before the endof the run at which the valve controller will return tozero hence stopping the floor operation and clearingthe machine. When set on zero, the machine willcontinue functioning until the distance reads zero. Thisfunction is adjustable between 0 and 10 metres with increments of 0.5 m.The operator can press UP or DOWN to adjust this value. Press MODE to continue.

Shut Down TimerThe shut down timer controls the time that theController will stay powered up while running onbattery power.The operator can press UP or DOWN to adjust thisvalue. Press MODE to continue.



21

Checking Setup Parameters

A Function screen is available to check current settings. To enter, press and hold the leftarrow for three or more seconds.

The top line shows the requested valve position. The second line shows the present gross load weight. The third line shows the current machine ground speed. The bottom line of the screen shows the current mode of operation (Std), the

Controller software revision and connectivity status.

The Function mode screen is shown below:

By pressing the UP or DOWN buttons, you can scroll and view parameters. They cannot bechanged here.

Press GO or STOP to exit and return to the operating screen.

VALVE: 38%GROSS: 2850kgSPEED: 5.65km/hMODE:Std Rev 3.5

Requested valve position

Gross weight

Ground speed

Controller software revisionCurrent operating mode



22

Factory Parameter Settings

Software Revision: Remote Display 3.4, Controller 3.8

To enter set-up, press TARE/GROSS and ZERO together for 4 seconds or until the set-up screen appears.

Press MODE until the correct parameter is displayed. Press UP or DOWN to adjust the parameter. Press STOP to exit the configuration screens. Remove power from the Controller to update changes.

Parameter ValueScale Damping Value 6.00Load Cell Type 5000.00 kgNumber Of Load Cells 4.00Load Cell Sens. 2.00 mV/V (PT) or 2.20mV/V (Kelba)

2.00mV/V (PT)Scale Hysteresis 10.00 kgScale Increments 10.00 kgWheel Sensor Fitted YesWheel Diameter 760.00 mmNo. of Wheel Holes 15.00 or 23 (check)Low Batt Level 11.50 VValve Fitted YesMax Valve PSI 2250.00 psiMin Valve Setting 30.00 %Valve Ramp Up Time 0.00 secValve Ramp Down Time 0.00 secValve Startup Dist. 85.00 %Speed Mode Min Speed 1.00 km/hSpeed Mode Max Speed 10.00 km/hSpeed Mode Strt Time 1.00 secDist. Before Finish 1.00 mShut Down Timer 20.00 min

Note: These are factory default settings. Some machines will require different settings.



23

Final Check

Check that the Controller is working correctly:Plug in the 7-pin plug into the tractor and turn on the power switch. This applies power to theController. The POWER LED on the Controller should be illuminated. Unplug the 7-pintractor plug. A battery power symbol ( ) will show on the screen which indicates the systemis running on battery power and the wagon is not plugged into the tractor.

After disconnecting the 7 pin plug and waiting 20 minutes (depending on parameter setting),the Controller should power down. If tractor power is reapplied, the Controller will restart.Note: To force power off and preserve battery power, press and hold the OFF button on theController when tractor power is disconnected.

Check that the Power module is working correctly:When the wagon is plugged in the tractor, voltage should be higher than when unplugged.Plugged in should read approx 13.9 – 14.5V.Unplugged should read approx 11.5 – 12.8V.

Check that there is RF communication:There should be an antenna symbol ( ) displayed in the bottom right hand side of thescreen.

Check that the valve (if fitted) is working correctly:Change the mode to Std, increase the ‘FEED RATE’ to 100% and press GO. The ControllerLED will be illuminated when the valve reaches 100% setting and the valve solenoid willmake a light buzzing noise. The wagon floor chain should start and stop when GO or STOPis pressed. System hydraulic pressure can sometimes cause the floor to not quite stop. Inthis case, increase tractor revs and recheck.

Check that the load scales (if fitted) are weighing correctly:This can be done by applying a known load to the floor after zeroing.The Weight module LED labelled ‘Weight’ should be illuminated whenever the system isrunning.If the weight display is unstable when stationary, charging the battery will help.The voltage will be displayed on the lower line of the screen. When the system is running onbattery power, a ( ) symbol will display alongside the voltage reading.

Check that the wheel sensor (if fitted) is working correctly:Jack up the wheel with the wheel sensor fitted and check that the sensor light blinks for eachhole while the wheel rotates. The green LED labelled PROX in the weight module shouldalso blink at the same time as the sensor light.

In distance mode, dial up a distance of say 20 metres on the Remote Display and press GO.Rotate the wheel 2-3 revolutions (forward or reverse) and check that the distance isdecreasing.

All complete:Ship with battery connected (it will power down to preserve power).



24

Technical Section

Power and Charging

The wagon must be connected to the tractor for the floor control solenoid (if fitted) tofunction and to charge the system battery.

When load cells are fitted, the forage wagon also includes a battery. This is chargedautomatically from the tractor power. The tractor does not need to be running (but can be)for this to happen but the wagon does need to be plugged in and power turned on. If thebattery is flat, this will usually take 7-8 hours depending on the age, state, and cyclingpattern the battery has experienced.

The Controller will continue to measure and report weight for approx 20 minutes after thetractor has been disconnected. This enables the operator to load the wagon using thetractor and still read the wagon weight. It then turns itself off if not plugged into the tractorwithin this time.

If the controller begins to lose communication or the weight reading becomes unstablewith the forage wagon when unplugged, it may be because the battery is weak or flat. Thebattery voltage indicator should show this.

Battery voltage (12V 7Ahr SLA) State of charge12.60+ 100%

12.50 90%

12.40 80%

12.30 70%

12.20 60%

12.00 50%

11.90 40%

11.75 30%

11.60 20%

11.30 10%

10.50 0%

Avoid discharging the battery belowthe 40% level whenever possible.



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System Display LEDs

There are LEDs located on the Controller panel and inside the Weight module to indicateoperational status.

Controller Module

Power LEDThe Power LED will be illuminated if:

1. Tractor power is connected or2. The battery is connected and the Controller is still running.

RF LEDThe RF LED will flash when the Controller receives an RF message.Pressing a button on the Remote Display instigates RF messages tothe Controller.

Note: The antenna symbol ( ) on the Remote Display indicates that itis receiving RF messages.

Weight LEDThe Weight LED will be illuminated when a message is received fromthe Weight module.

Valve LEDThe Valve LED will be illuminated when:

1. Required valve percentage is greater than 5% and2. Actual valve percentage is within 2% of required valve percentage and3. Controller is receiving current feedback from valve.

Weight Module

Prox LEDThe Prox LED will be illuminated when the wheel sensor sensesferrous metal.

Comms LEDThe Comms LED will be illuminated when receiving data from theController.

Weight LEDThe Weight LED will be illuminated when the load cells are connectedcorrectly and the weight is within a valid range (100kg load per cell orgreater) I.e. off for a short circuit or an open circuit, on otherwise.

Power LEDThe Power LED will be illuminated if 12V power is supplied.



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System Safety Fuses

The entire control system is protected by three separate fuses located in various positions.

1. Installation loom fuseThis is located on the positive (+) wire at the power source end of the installation loom. Thisprotects the entire system from short circuits. The fuse used is a 5A (yellow) automotiveblade type (see below).

2. Battery cable fuseThis is located on the positive (+) wire of the battery connection cable. This protects thecharge system against reverse polarity from incorrect battery connection.The fuse used is a 5A (yellow) automotive blade type (see above).

3. Power charge circuit board fuseThis is located on the power charge circuit board to protect the system from short circuitsparticularly if fuse #1 has been replaced with a heavier rating or similar.The fuse used is an M205 8A.

Radio Frequency Device

The Remote Display communicates with the wagon by a wireless link and must be withinrange of the forage wagon for the system to operate correctly. If the Remote Display is notable to communicate with the Controller, the antenna symbol ( ) will disappear or not show.

Common reasons are:

Local interference from a strong radio frequency source such as cell phone, power pylonsor R.T. site.

Distance between the Remote Display and Controller is too great. (Moving back withinrange will allow the system to begin operating again.)

No power to the Controller (not plugged into tractor power or if fitted with a battery hasauto-powered off).

Physical medium in the signal path from the Remote Display to the forage wagon (e.g.metal farm shed).

Remote Display and Controller operating on different RF channels. Interference being caused by an adjacent farm using similar machinery. RF channel

should be changed to prevent further interference.



27

Wiring Schematic



28

Wiring Schematic V2



29

Cable Descriptions

TCS-LOOM2 Tractor Cable – 7 pin plug to power module boardPin # Wire Colour Description

1 Yellow Left flasher2 Black RF (+) supply3 White and Blue Earth and RF(-)4 Green Right flasher5 Empty -------------6 Red Stop light7 Brown Tail light

7-Pin plug (viewed from rear of plug)

TCS-V2LOOM1 Tractor Installation LoomWire Description Wire Colour Connects to:

Positive Brown Tractor battery & 7-pin plug (pin 2)Negative Blue Tractor battery & 7-pin plug (pin 3)Positive White Remote display plugNegative Blue Remote display plug

7-Pin socket (viewed from rear of plug)

TCS-V2CABBAT Battery Cable – Battery to power module boardWire Description Wire Colour

Positive BrownNegative Blue

TCS-V2CABCON Power Cable (Red sheath) – Controller plug to power modulePin # Wire Colour Description

1 Red V+ out Tractor3 Blue V+ out Battery4 Green 0V out



30

TCS-V2CABVAL Valve Cable – Controller plug to valve plugController Plug Pin # Wire Colour Valve Plug Pin #

1 Brown 14 Blue 2

TCS-V2CABWGT Weight Cable (White sheath) – Controller plug to weight modulePin # Wire Colour Description

1 Red V in2 White D +3 Blue D -4 Green 0 V

Remote Display Screen Contrast

The contrast of the remote display screen can be altered by following the instructionsbelow.

1. Remove the back cover plate.2. Locate blue adjuster pot on the top circuit board.3. Adjust yellow screw in centre of pot (clockwise for lighter text).

Caution: Adjuster is very sensitive.

Note: Opening the back cover voids the factory warranty. Check with the dealer first if unsure.

Software Revisions

Hardware Date Rev Comments

Controller module 7.12.07 3.8 First release of Generation II5.05.08 3.9 Adjusted weight field for one more digit. Adjusted scales

mode so that mode button does not reset TO FEED Weight.

Display module 15.10.07 3.4 First release of Generation II

Weight module 7.12.07 1.2 First release of Generation II

12

1

23

4 Valve end plugController end plug



31

Fault Diagnosis

Problem Issue Solution

Controller won’t turn on whenwagon is plugged into tractor Power not getting to Controller

Check fuse in Power module

Check fuse in wiring loom

Check wiring from tractorController won’t turn on when theGO button (on Controller) ispressed.

Battery is disconnected or flat Reconnect or recharge battery

Battery fuse blown Replace fuse

Controller won’t stay turned onwhen unplugged

Battery flat or not holding charge Plug wagon into tractor torecharge battery

Battery not connected Connect battery

Battery fuse blown Replace fuse

No communication indicator ( )showing on Remote Display

Controller not operating Check wiring from tractor andfuse in power module

Signal interference from anothermachine Change RF channel

Distance too great betweenController and Remote Display Move closer together

Signal blocked by large object Move away from objectController and Remote Displayare operating on differentchannels

Change both units to the samechannel and re-power

Scale reading fluctuates

Low battery voltage Check wiring from tractor andfuse in power module

Loose or faulty load cell wiring Check load cell wiringLoad cell cables gettinginterference from power cables

Separate load cell and powercables

Floor won’t move forward when inStandard or Weight mode.

Power not getting to Controller Check plugs and wiring

System not started Press GO on keypad

Feed rate too low Increase feed rateDamaged valve cable or faultysolenoid coil Check cable and/or coil

Floor not moving forward when inDistance or Speed mode

Power not getting to Controller Check plugs and wiring

System not started Press GO on keypad

Faulty proximity sensor or wiring Replace sensor/check wiring

Floor won’t stop coming forward

Override knob is screwed in Unscrew override knob (anti-clockwise)

Faulty override cartridge Screw out override knob orreplace valve cartridge if faulty

System still running Press STOP on keypad

Scales won’t read at all or displayreads 0kg

Loose, faulty or incorrect load cellwiring Check load cell wiring

Weight module not connected Check connection



32

Troubleshooting Chart

giltrap generation ii rf control system...rf gen ii system technical manual rev02_12_10.doc 2...

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