Operating Manual - Nutridose Controller with Conductivity probe
Contents
1. B349D Battery Voltage in milli Volts TO18A Temperature in tenths of a degree C FOO Overflow flag JOO Pump On Status 00 Pump Off 01 Pump On K00000000 The length of time that the pump has been on in milliseconds K00000000 if the pump status is OFF L000002F2 Pump ON time for last complete injection in milliseconds M05C7 The measured Solenoid current for the last dose in milliamps OOE5F The measured Pump current for the last dose in milliamps D0235 The last measured conductivity in microsiemens X03E8 The user set conductivity value over which water meter pulses are blocked in microsiemens Y09C4 The user set conductivity value over which a conductivity alarm is generated in microsiemens The checksum character End of message character Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 31 16 3 4 X Stop dosing This command will set the 0121 controller to stop mode The 0121 will close the gate valve and stop dosing There is no command to switch it ON It can only be switched on by pressing the GO button on the front panel Response The response from this command is the same as for the status command however X is returned in place of S in the status return string Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nu2. O O O z Run Stop Alarm Solenoid O O O Battery Charging Pump O Nutrient O Gate Valve O CB Radio Remote O CONDUCTIVITY gt s Water O comms PROBE T GATE POWER WATER x lt m Z E 2 NUTRIENT VALVE RELAY METER NOAA segg B 229508 ooh 2 EELER E RE 1 D60422 29zZzz 22802002 Rkk e E 1234567 8910111213 14151617 18192021 22 23 24 25 26 27 28 29 30 31 31 3233 8 e ds o 2 2 5 a Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 33 17 1 Telemetry Tone Pulse sequence GME TX3200 The 0121 can be connected to a GME Electrophone TX3200 CB radio The connection between the 0021 and the TX3200 is made using a length of 6 wire flat phone lead crimped into a 6 pin RJ12 connector Note that some RJ12 connectors only have 4 pins fitted but that the full 6 pin version is required in this application The value of R1 used in the trial was 470R however the value will still have to be selected to set the desired volume in each application A small leaded trim pot can also be used The RJ12 cable plugs into the front of the TX3200 in place of the microphone BER oeo SZ SZ SZ Okt O 25 26 27 28 29 aN RJ12 6 pin Connector Blue Yellow Green SS be Black White MIC GND End View Side View Syndetic PTY LTD 101 Hyde Rd Y
3. YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 10 9 0121 Control Unit Operation D Pastoral A Feedlot Systems ml 17 Railway Road FAIRFIELD 4103 a Tel 07 3848 5290 Fax 07 3848 5231 Nutridose Controller Monitor Solenoid O O O Battery Charging Pump O Nutrient O Gate Valve O Remote O HE OG O O e Run Stop Alarm CONDUCTIVITY gt 1 A E Water comms PROBE ATE POWER WATER x x lt m Bd Eo 2 NUTRIENTVALVE RELAY meten Aarm mey C E amp lt a EEA E EE lla E E EE S ORR S Zore i 4 4 aa corzo m KEE 21234567 8 9 10111213 14151617 18192021 22 23 24 25 26 27 28 29 30 31 31 32 33 There are some differences between the new Nutridose controller designated 0121 and the old Nutridose controller designated 0021 which did not have conductivity measurement capability For a detailed description of the function of each LED see section 12 9 1 Starting and Stopping Pressing the GO button starts the system The 0121 will open the gate valve and when a water meter pulse is received the system will start the pump and deliver a dose of nutrient To prime the pump press and hold the Go button The RUN LED will be lit To stop dosing press the STOP button The system will close the gate valve and will not operate the pump The STOP LED will be lit indicating that the system has stopped If an alarm condition occurs th
4. a description of alarms Press the Enter button to go to a sub menu that allows you to see detailed status information Press the Enter button to go to a sub menu that allows you to see set parameters that control how the unit works This menu displays the duration in Days Hours and minutes and the total volume of Nutrient injected during that time The time and the nutrient volume are both reset to zero by going to the RESET NUTRIENT LOGGING menu in Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 15 13 3DEBUG Menu the CONFIG sub menu They are also set to ZERO when the CPU re starts The information is not retained if the power is lost from the system The example display shows that 1105 milliliters of nutrient have been injected in the last 1 hour and 24 minutes To get into the DEBUG menu from the main menu use the arrow keys to get to the DEBUG menu and then press enter to get into the DEBUG menu You know when you are in the DEBUG DEI menu because there is a the ESC key to return to the main menu indicates Debug menu Wi Pig U23 N PLS 1234 SERIAL 01 S BATTERY S 12 445V SYSTEM CURRENT 67mA LAST SOLENOID OmA LAST PUMP Ze OmA in the top right of the display If you are not changing a value press This menu displays the pulses as they are received Thi
5. aaa eee atin 15 13 4 CONFIG Mer eege tege seein sit an en te Ae ie 16 14 Appendix 3 Connections 2 2 Astana iain liada 19 14 1 Conductivity Probe incu tan een naan tasa 19 14 2 Solar KEE 19 14 3 Battery ci ii bea bate caves Weeden ae eee ee ees 19 14 4 PUTI ee be then eet ite e ee A a 19 14 5 Nutrient Meter ER O ias 20 14 6 Loterie ia 20 14 7 Nee EE 20 14 8 Walter Motero ik E ee i i eee ee 20 14 9 Solenoid EE 21 E A BE Eu EE E 21 TATI Alarm le 21 14 12 Serial Remote Control COMMS interface ooocnnncinnnnnnnnccnnnccnnnnnnnccnnnnc cnn rra 22 Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 3 15 Alarms and Fault Fmmdmmg nano ncnc nano nn nc nnno nn nr nnn narran rra 23 16 Remote Control dia 26 16 1 Protocol Seu iii 26 16 2 EE ea ios Mel tree cere 26 16 3 Commands and responses cccccccccccocccononanononcnoncnnnnnn canon cnn nc cnn n nana cnn nn r anna nan nnne nnn 27 16 3 1 C Stream Conductivity Data 27 16 3 2 D Stop streaming data from C commande 27 EE EE 27 16 3 4 X Stop dosing E 31 17 Tone Pulse Telemetry saa A A ntc 32 17 1 Telemetry Tone Pulse sequence GME TX3200 coconccccccccccoccconoccnonccccnncnnnn cc nana cnnnncnos 33 18 Connection as a Controller connccccnncnnnnncnnnccnnnccnno rana nano rnrr cnn 34 Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Contr
6. the user no alarms Bit 2 Conductivity Monitoring enabled disabled 0 Conductivity monitoring OFF 1 Conductivity monitoring ON Bit 3 Current Monitoring enabled disabled 0 Current monitoring OFF 1 Current monitoring ON 00 Run 01 legacy Alarm 02 Stop 03 Alarm 04 Run amp Conductivity 05 n a unexpected 06 Stop amp Conductivity 07 Alarm amp Conductivity 08 Run amp Current 09 n a unexpected OA Stop amp Current OB Alarm amp Current 0C Run amp Conductivity amp Current OD n a unexpected OE Stop amp Conductivity amp Current OF Alarm amp Conductivity amp Current G01 Gate Valve Status 01 Gate Valve Open 00 Gate Valve Closed R01 Remote Power Relay Status 01 Energised 00 De energized W000109F0 Water Usage logged in the duration indicated in liters NOOOA599F The Amount of nutrient logged in ml P0064 If the unit is in Nutrient Mode then this contains the desired nutrient dose in hundredths of The first character will be P in Nutrient Mode i e P0064 Nutrient Mode 1 dose percentage If the unit is in Timer Mode then this contains the desired pump on time in milliseconds The first character will be Z in Timer Mode i e Z03E8 Timer Mode 1000millisecond pump on time Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 30
7. to key a telemetry transmitter Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 14 13 Appendix 2 Menu System This appendix describes the Liquid Crystal Display LCD menu system 13 1Navigating the Menus Use the up and down arrow keys to move from one menu display to the next To select or modify an item press the ENTER button If the item can be adjusted then square brackets will be placed around the item If you make a mistake and do not wish to change item press the ESC key ESC stands for Escape and it means escape or cancel from this item and go back to where you pressed the ENTER button 13 2 Top Level Menu NUTRIDOSE LS VEO OS x Part Hardware Software Number Revision Version NUTRIENT DOSE 00 00 SEC 20 00 ALARMS NO ALARMS DEBUG MENU ENTER TO VIEW CONFIG MENU ENTER TO VIEW D HH MM NUTRIENT DOLAR OOO da When power is applied the unit will display a start up screen as shown below Press the down arrow to get to the next menu item This display gives two pieces of information The left hand number shows the time of the dose and the right hand number shows the concentration dose Note that if you ignore the decimal point in most cases the number can be read as ml If an alarm is present this menu item displays the reason for the alarm See Appendix for
8. used Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 17 NUTRIENT CAL 1295 Pulses SERIAL ADDRESS 01 COND MONITOR ENABLED COND BLOCK LVL 1000uS COND ALARM LVL Z5000S ALARM MODE LATCH REALTIME TEST ENABLED This menu is used to set the number of pulses per litre generated by the nutrient flow meter This menu is used in conjunction with the serial remote control interface 01 is the address of the unit See section Protocol Format To change the address of the unit Press Enter Then use the up and down arrows to set the address The address is a two digit number Press Enter again to store the new address Once stored the address is retained even when power is removed from the unit This menu is used to enable or disable the conductivity monitor function If it is set to disabled then the unit does not measure conductivity or generate alarms related to conductivity This menu is used to set the level at which the unit will ignore pulses from the water meter That is if the conductivity is greater than this level but less than the CONDUCTIVITY ALARM level the unit will ignore pulses from the water meter until the conductivity drops 10 below this level This menu is used to set the conductivity alarm level If the conductivity rises above this l
9. 21 For additional safety a gate valve can be added to the system and controlled by the 0121 11 1Conductivity Probe Interface The conductivity probe communicates via a RS485 physical interface The conductivity interface is completely separate from the remote control interface Additional information on the remote interface will be provided in the manual Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 12 12 Appendix 1 LEDs This section describes in detail the function of each LED on the unit 12 1RUN LED GREEN ON indicates that the system is in automatic mode and that nutrient is being injected at the correct level 12 2STOP LED RED ON indicates that the unit has stopped by the operator pressing the stop button or a STOP command being received over the remote control interface 12 3 ALARM LED RED ON indicates that there is a problem either with this box or with the system being monitored The reason for the ALARM LED being ON will be displayed on the LCD This LED is a latched alarm and the user must press the GO button to restart the system 12 4 Battery LED GEEN On indicates that 12V battery is connected to the system 12 5 CHARGING LED GREEN The 0121 unit contains a solar panel regulator circuit to control the charging of a lead acid battery from a solar panel The LED is on when the internal FET switch is clo
10. Conductivity Probe Pin 1 PWR 12V unregulated DC supply from the battery to the conductivity probe 2 GND Power Ground 3 RS485 A 4 RS485 B 5 No internal connection Reserved RS485 is a bi directional data interface using 5V logic levels These lines are used to communicate with the conductivity probe The conductivity probe connection uses 9600 bps 1 start 8 data 1 stop bits No parity 14 2Solar Panel These two connections connect to the solar panel Pin 6 Solar Panel Negative 7 Solar Panel Positive The unit can tolerate the solar panel being connected the wrong way round for a short time without damage During that time the CHARGE LED will be twice the normal brightness 14 3Battery These two terminals connect to the battery Pin 8 Battery Negative Also referred to as Ground and GND 9 Battery Positive The unit can tolerate the battery being connected the wrong way round for a short time without damage The unit will not operate in this mode An inline fuse should be installed between the battery positive and the battery 14 4Pump The 12 V pump is connected across these terminals Pin 10 Pump positive connection This pin is switched to the Battery pin when the unit is in RUN mode 11 Pump negative Momentarily switched to Ground to turn on the pump The duration is controlled to obtain the required proportion of nutrient to water WARNING DO NOT connect any wires between the pump and the
11. ERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 34 18 Connection as a Controller This is the standard method to connect the 0121 when it is to operate as a controller Nutridose Controller Monitor Solenoid O O O Battery Charging Pump O Nutrient O Gate Valve O Remote O aA Pastoral amp Feedlot Systems mln 17 Railway Road FAIRFIELD 4103 y da Tel 07 3848 5290 Fax 07 3848 5231 OJO 00 E dei D CONDUCTIVITY z GATE POWER 5 Water comms WATER x S 2 3 UTRIENT VALVE RELAY METER ZG Mam Relay QF E lt m E az a w 53833 2233 ESTE 023 P 333322773 a O la 122028 WC RRC RRC 12 4567 7 18 19 20 21 22 23 24 25 26 27 28 29 30 31 313233 Solar Panel Battery S From Nutrient Tank Nutrient Solenoid Gate Valve volume Valve meter To Drinkin Water Supply Trough Injection Water Mixing Conductivity Point Meter Pipe Probe Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au
12. M 0121 Manual Nutridose Controller with Conductivity Probe Pastoral 8 Feedlot Systems ABN 84 092 508 239 43 Esplanade Brisbane Australia Tel 07 38485290 Mob 0412894943 Fax 07 38485231 email nutridose gmail com Website www nutridose com au User Manual 0121 Nutridose Controller with conductivity probe Syndetic Part Number 0121 Document Number M 0121 Document Revision History REV Description Date Who A Original Issue 05 JUN 2006 Frank Thomson B Draft notification removed Section 9 Fixed cross reference to 28 AUG 2006 Frank Thomson section 12 for the description of the function of each LED Deleted heading 9 3 Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 2 Contents To ai fete e 4 2 Safety and Warnings and declaimers narran crac 4 ed UTA WANNA ere a reer t eee a 4 2 2 Static Sensitive COMPONENMS ccccceceeeceeneceeeeeceaeeeeeaeeeeaeeceeeeesaaeeeeaaeseeeeeseaeeeseaeeneaeeseaes 4 3 System Block Diagram cceccccecececeeeeeceeeeeeeaeeeeeeeeeeeeecaaeeeeaaeseeeeeceaeeesaeedeaeeseeeeessaeeseaeeeeneeee 5 d System Cp ratlon Edge EENS EENS viel ge ENEE Ree eege 5 5 GontrolMOdeS iia iia 7 5 1 Nutrient Meter Dosing Mode 7 5 2 Timer Mode EE 7 6 Built in Safety and Monitoring functions eeeceeseeceeeeeeeeeeeeeee scenes caaeeeeaaeseeeeeseaeee
13. alarm relay output on pins 21 and 22 Pin 28 Tone 29 Ground Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 22 14 12Serial Remote Control Comms interface This is the physical interface for the remote control interface This interface is described in more detail in Remote Control Both RS232 and RS485 physical interfaces are provided They connect to the one UART inside the unit When the 0121 transmits the data comes out on both interfaces When it is listening it is listening to both inputs The user should use one or other but not both interfaces Pin Function 30 GND Comms interface ground pin 31 RS232 TX Data Output from the 0121 32 RS232 RX Data Into the 0121 33 RS485 A 34 RS485 B Data is transmitted at 9600 bps 1 start 8 data 1 stop No parity Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 23 15 Alarms and Fault Finding The system can display a number of alarms on the ALARM menu If the unit is being accessed via the Remote serial interface then a code number is returned Remote Alarm Code LCD Display 0 NO ALARMS 1 LOST POWER The unit lost power Check the battery and the wiring to the battery If there is a bad connection to the battery then the voltage can drop too low when the
14. battery to test the pump This will damage the 0121 controller If you wish to test the pump motor disconnect Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 20 BOTH WIRES from the 0121 controller 0121 controllers damaged by the addition of wires to test pumps are not covered by warranty 14 5Nutrient Meter These three connections connect to the nutrient flow meter The meter requires positive voltage supply and ground It returns a digital 0 5V signal that is read by the microprocessor It is designed to interface to a RS 256 225 flow meter Pin 12 GND Braid 13 5V Supply to Meter RED Wire 14 Pulses BLUE wire 14 6 Gate Valve A Spray Flow series 2400 or equivalent gate valve is connected across these three terminals Pin 15 GND Gate Valve ground connection WHITE wire 16 Gate valve control output BLACK wire When this is at 12V the valve opens When this is at OV the valve closes 17 12V supply output to gate valve GREEN wire 14 7Power Relay This is a relay output that is used to switch the power of a monitored external system The relay is energized when the unit is running and de energized when the system is stopped or in alarm mode It can switch 12V DC 10A Pin 18 NO Connected to Pin 20 when all OK 19 NC Connected to Pin 20 when an alarm is present 20 Common 14 8 Water Meter This input
15. ch higher than the background level and the alarm and warning thresholds will have to be set low and close Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 9 together This may result in the system either shutting down unnecessarily or missing over dose situations 8 Some real data This test was done with two tanks of nutrient mix One tank had the correct concentration and the other tank was filled with a mix that had been made up at twice the normal strength At the point shown on the chart the nutrient feed pipe was switched from one tank to the other As you can see it took a number of doses for the stronger mix to flow through the system Once the concentration crossed the threshold the unit shut down E Virtual Chart Recorder v2 2 2 MEE YA e l Conductivity crosses ALARM thrshold Unit shuts down Conductivity increasing as stronger mix comes through Normal Doses 2 H Nutrient intake pipe switched eege 26 10 10 26 22 10 26 34 10 26 46 10 26 58 10 27 46 10 27 58 10 28 10 10 28 22 10 28 34 10 26 46 10 28 58 10 29 11 10 29 23 10 29 35 10 29 47 10 29 to double Chart position Lock strength mixture gt Ge Syndetic PTY LTD 101 Hyde Rd
16. character terminates the transmission 16 2Checksum The checksum operates on the address and message bytes only It is a single character and is calculated as follows SUM AND 63 XOR SUM DIV 64 32 Where SUM is the modulo 256 sum of the address and message bytes AND is the bitwise AND operator XOR is the bitwise exclusive OR operator DIV is the divide operator This is equivalent to saying that the checksum is the eight bit sum of the ASCII values of the address and message characters with the most significant bits of the result shifted down and exclusive ORed with the two least significant bits of the result The 32 space is added to make the result printable Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 27 16 3 Commands and responses 16 3 1 C Stream Conductivity Data This command repeatedly sends conductivity measurement data out the serial port Note that the response is NOT formatted like the other messages This command is intended to be used in debugging or lab situations where the 0121 is connected to a pc Note that this only works when the conductivity sensor is connected to the unit Use the D command to switch it off Example 01CF Once this command is received the unit streams data in the following format at 10 samples per second Example Response 01 463 1000 2500 0 1 E The meaning of this
17. en the system will shut down and the ALARM LED will light 9 2 Using the LCD and Entering Data Use the up and down arrow keys to scroll through the menus The unit has two levels of menus There is the top level menu that displays key information The Config menu is used to enter data such as the dose time or percentage concentration and the alarm levels and other parameters The DEBUG menu is used to view various things such as the actual measured conductivity To select an item press the ENTER button To stop entering data press the ESC button Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 11 Top Level Menu Config Menu Debug Menu 10 Telemetry and Remote Control The unit retains the serial remote control interface The D Type connector has been changed to a Phoenix screw terminal connector and now both RS232 and RS485 physical interfaces are provided The standard status string that the unit produces has been expanded to include the conductivity measurement and a new command has been added to stream conductivity data to the PC for plotting or analysis 11 Monitoring Other Systems This unit can be used to monitor an external dosing system and to shut it down in the event of an overdose situation being detected There are several ways to this The power to the external system can be switched through the Power Relay on the 01
18. evel then the unit shuts down into Alarm mode PULSE or LATCH is displayed to advise the mode of operation of the Alarm Relay To change the mode of operation of the alarm relay Press ENTER then use the up and down arrows Press ENTER to store the value or ESC to cancel The value stored is retained even if the battery is disconnected from the unit When set to LATCH the relay is energized when there is no alarm and de energized when there is an alarm When set to PULSE the Alarm Relay pulses on for a couple of seconds once per minute When set to ENABLED the Nutridose system will check that the solenoid and pump currents are within the limits described in section TBD_ as well as checking that pulses are coming out of the nutrient sensor as the system doses Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 18 This menu is used in conjunction with the nutrient RESET NUTRIENT log on the main menu LOGGING Press ENTER to reset both the time count and the nutrient usage count to zero The system will respond asking you to confirm the reset Press ENTER to confirm or ESC to cancel Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 19 14 Appendix 3 Connections This section describes the physical interfaces on the unit 14 1
19. high and the back pressure is high then the system may not be able to deliver the dose in the available time Upgrade to a larger dosing system b A faulty register in the water meter c Water hammer or other hydrological effect causing the water meter to run back and forward 8 CHECK SOLENOID The 0121 controller measures the current to the solenoid just before the pump is switched on If the current is too high or too low then this alarm is generated The most likely cause is the wire to the solenoid or the solenoid being open circuit or shorted out OK Current Range 250mA gt 3000mA 9 CHECK PUMP The 0121 controller measures the current to the PUMP during the dose If the current is too high or too low then this alarm is generated The current can be too high if the pump jams or if the system has a blockage or the back pressure in the water line is too high or if the wire to the pump is short circuited The current can be too low if the wires are broken or the motor is open circuit This alarm can be generated if there is no nutrient in the pipe OK Current Range 500mA gt 11000mA Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 25 10 CONDUCTIVITY TOO HIGH ALARM The 0121 controller measures the conductivity of the water after injection If the measured conductivity goes above the thresh
20. ion before using the process or this equipment 2 Safety and Warnings and disclaimers 2 1 Urea warning Too high a concentration of urea can kill cattle Many safety interlocks have been included into this controller to try to protect against incorrect dosage However there is NO guarantee that the system is fail safe In the event that the 0121 controller shuts the system down the complete system should be examined to determine the source of the fault Regular maintenance of the system especially moving parts is essential for reliable system level operation Do nat rely on software interlocks in the 0121 controller to compensate for faulty or poorly maintained hardware in the rest of the system 2 2 Static Sensitive Components The 0121 controller contains electronic components that are sensitive to static electricity The unit should not be dismantled in the field and should only be opened at a static safe work station Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 5 3 System Block Diagram Nutrient Concentrate Tank Nutrient volume Solenoid meter Valve Gate Injection Valve Pump 0121 System Controller Float Valve Water Supply Injection Water Mixing Conductivity Drinking Trough Point Meter Pipe Probe 4 System Operation The system operates as follows When the cattle start to drink fro
21. is designed to monitor the reed switch detector in the main line water meter Pin 21 GND 22 Data Input from Reed switch Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 21 14 9Solenoid These pins are used to connect to the Solenoid The solenoid opens momentarily before the pump operates and closes when the pump switches OFF Pin 23 ve output 24 ve switched output This output has a low side switch FET like the pump 14 10 Alarm These 3 pins connect to a small telecommunications style relay that is used to indicate an alarm condition to a telemetry system The relay operates in one of two modes depending on the setting in the ALARM menu If the mode is set to PULSE then When the system is in the alarm state the relay closes for 5 sec every minute It is intended to key a radio transmitter to transmit the alarm condition as a tone If the mode is set to LATCH then When the system is in the alarm state the relay is permanently closed In this mode the alarm would be transmitted via a telemetry system Pin 25 NO Connects to pin 22 when an alarm is present 26 NC Connected to pin 22 if no power on the system 27 Common 14 11 Alarm Tone This output provides a tone sequence that can be transmitted over a two way radio to alert the user to a problem with the system The radio is keyed to the transmit condition using the
22. m the trough the water float valve opens and the water flows in the line The water meter measures the flow and every ten litres it sends a pulse to the controller The controller is triggered by the pulse from the water meter and operates the injection pump to inject a measured dose into the water supply The Nutrient volume meter is used to measure the dose and the pump time is adjusted to ensue that the correct dose is made This helps to compensate for varying back pressures The water with the 100ml urea dose flows through the mixing pipe This pipe will vary from installation to installation depending on flow rates The conductivity probe measures the conductivity of the mixture Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 6 Over Normal Dose Dose Conductivity ck Unit shuts Conductivity down Crosses the ALARM threshold A Alarm Level Conductivity Conductivity crosses crosses BLOCKING BLOCKING threshold threshold ve re armed BLOCK Se Level a Water Water Meter Time Meter locked out Can Water Pulse not be triggered Meter Triggers while the Pulse dose conductivity is Triggers When the conductivity is below the warning threshold the system is armed to receive a pulse from the water meter When the pulse arrives the system starts the dosing pump and injects a single 100ml dose As the
23. message is made up of the following bits Start of message character 01 The address of the unit 463 The measured conductivity value in micro siemens 1000 The value at which water meter pulses are blocked in micro siemens 2500 The value at which a conductivity alarm is triggered in micro siemens 0 The current dose proportion for the dose in percent 1 The state of the main water meter input 0 Water meter contacts closed 1 Water meter contacts open E The checksum The end of message character 16 3 2 D Stop streaming data from C command This command switches off the function initiated with the C command Example 01DG There is no response on the serial interface 16 3 3 S Status The Status command requests that the Nutridose return a message providing its status Example 01SV The meaning of this message is made up of the following bits Start of message character 01 The address of the unit S The status command V The checksum The end of message character Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 28 Example Responses 01 S VOA02 CO00056DD A00 S03 G01 R01 W000109F0 NOOOA599F P0064 B349D TO18A F00 J00 K00000000 LO00002F2 M05C7 O0E5F D0235 X03E8 YO9C4 C Character Description Start of message Character 01 The address of the unit sending the message 01 in this exam
24. old entered in the COND ALRM LEV menu then the system shuts down and this alarm is reported 11 CONDUCTIVITY PROBE NOT RESPONDING This alarm can only be generated if conductivity monitor is enabled in the CONDUCTIVITY MONITOR menu This alarm means that the 0121 controller expects to be able to communicate with a conductivity probe but that it is not able to communicate with the probe Check the wiring to the probe Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 26 16 Remote Control This section described the remote control and monitoring protocol The details of the serial port interface are described in section Serial Remote Control Comms interface 16 1 Protocol Format lead in Address Message Checksum Terminator Both transmit and receive messages fit this format All characters transmitted are printable ASCII with the exception that a CR LF is appended to each response generated by the unit The various message elements are defined as follows lead in The open curly bracket character Address The address of the unit in Hex Addresses can range from 00Hex to FFHex Two asterisks are recognised as a wild card address Message Message characters Printable ASCII characters Checksum Ckecksum as defined below Terminator The closed curly bracket character This
25. oller with Conductivity Probe Page 4 1 Introduction The Nutridose system is used to add a controlled amount of urea to the drinking water for cattle Typically a dose of 1 100ml dose of urea concentrate per 10 litres of water is used Obtaining the correct dose is critical as even a small under dose renters the system almost useless and a dose twice the required amount can kill cattle A number of factors can cause an overdose situation to occur These include 1 The urea concentrate can be accidentally prepared at the wrong strength 2 The system can malfunction and inject for too long a period 3 The water meter on the main water line can falsely trigger the dosing system Pure urea in water is not conductive however the urea mix includes salts that do increase the conductivity of the water The 0121 Nutridose controller includes a toroidal conductivity probe that measures the conductivity downstream of the injection point The advantage of the toroidal probe is that there is no metal contact with the water This means that there is much less chance of the probe measuring incorrectly due to a buildup of deposits on the probe This document is the user manual for operating the Nutridose controller This is a complicated and sophisticated system Please take the time to read and understand this manual If you have any questions please contact the supplier Ensure that you understand how the system works and the risks of using urea medicat
26. ple Ss The command received is echoed Note the space between the address and the echoed command distinguishes a response from a command VOA02 The Software version number Two bytes in hex the fist byte represents the whole integer value of the software version the second byte represents the fractional value of the software version Version 10 02 is shown in this example C000056DD The time count in seconds since logging was reset A00 The Alarm Code One byte transmitted in HEX When it is zero there are no alarms 00 No Alarms 01 Lost Power 02 Dosing Proportion High 03 Check Pump 04 Low Battery Voltage 05 Check Solenoid 06 Conductivity Too High Alarm 07 Water Meter Pulse While Solenoid On 08 High Battery Voltage 09 Conductivity Probe Not Responding 10 Pump On Too Long 20 Water Meter Pulse While Pump On 40 Check Nutrient Sensor Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 29 S03 The unit State The State byte determines how the unit responds this is a bit field The state of the unit is also reflected in the three LED s immediately below the LCD The states fields are set by the following Bit 0 Alarm mode Stopped with an alarm condition 0 Alarm mode OFF 1 Alarm mode ON Bit 1 Run Stop mode 0 Run mode Auto dosing mode 1 Stop mode Stopped by
27. pump runs and this can cause the unit to reset PUMP ON TOO LONG The pump was on for longer than the 3 seconds when dosing or 15 seconds when priming Check that there is nutrient in the tank Check for a blockage in the injection system Check that the nutrient flow meter is working properly and does not have material deposited inside it Check if the solenoid or gate valve are jammed closed Check if the pump is faulty WATER METER PULSE WHILE PUMP ON This indicates that a second pulse was received from the water meter before the unit had finished this dose cycle This can be caused by several factors a If the water flow rate is high and the back pressure is high then the system may not be able to deliver the dose in the available time Upgrade to a larger dosing system b A faulty register in the water meter c Water hammer or other hydrological effect causing the water meter to run back and forward DOSING PROPORTION HIGH This alarm can only be generated if the system is running in feedback control mode le when the DOSING MODE is set to NUTRIENT METER and if the proportion as calculated by the unit is greater than the level set in SET ALRAM LEVEL menu The proportion is calculated by taking the number of nutrient pulses then converting to milliliters using the NUTRIENT CAL factor and then dividing that into 10 litres and then comparing it to the ALARM LEVEL setting The first thing to check i
28. s information can be useful when fault finding The numbers increases by one each time a pulse is received on the respective input Internally 16 bit counters are used The maximum counts for water and nutrient that will be displayed are 65535 The counters then roll over to zero Note that RAW PULSE COUNT is displayed NOT proportion and NOT liters This menu is used to help with using the serial remote control function As characters are received from the remote interface they are displayed on the bottom left corner As a valid message starts to be received it is displayed across the bottom line This menu displays the battery voltage This menu displays the total system current This is the measured current draw of the solenoid when the solenoid was energized on the last dose cycle This is the last measured current draw of the pump when the pump was energized on the last dose cycle Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 16 This is the reading from the conductivity sensor CONDUCTIVITY Ous Press ENTER to run the self test The result of RUN SELF TEST X the test is displayed on the bottom line WARNING the self test will inject a small amount of nutrient 13 4CONFIG Menu To get into the Config menu from the main menu use the arrow keys to get to the config menu and then press enter to get into
29. s whether the nutrient sensor has got material deposited on it as this can cause it to have intermittent operation Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 24 5 LOW BATTERY VOLTAGE This alarm is generated if the battery voltage is below 10V Always ensure that a good quality battery in good condition is being used Batteries need to be replaced every couple of years Check the water level in the battery and top up with DEMINERALISED WATER if required Check the solar panel Even a small amount of shade over part of the solar panel will render the solar panel useless 6 CHECK NUTRIENT SENSOR This alarm is generated if during a dose that there are no pulses from the nutrient sensor in any twenty five millisecond period This can be caused by the sensor being gunked up by deposits in the water If this error is seen it is CRITICAL to ascertain the source of the problem and to fix it This may require the nutrient sensor to be replaced Simply re starting the system may result in a over dose situation 7 WATER METER PULSE WHILE SOLENOID ON This alarm is generated if a second pulse was received while the solenoid was open This indicates that a second pulse was received from the water meter before the unit had finished this dose cycle This can be caused by several factors a lf the water flow rate is
30. saeeseneeeeaes 8 6 1 Maximum Pump On Time 8 6 2 Conductivity Water Meter LOCK out 8 6 3 COnductivity Alarm sesiis ainai Nantinya iaaa iiiaae diaaa iega diran 8 6 4 Nutrient Meter Health oooonnncccnnnnnccnnnnnccccnnnoncccnnnorcconnnonc cnn rc nn 8 6 5 Double water Meter oulse noc cn anar rca 8 7 A Few Points to Bear In Mind nano cnn n nano nn a rnn nn 8 ER Le E EE 9 9 10121 Control Unit Operation ui oa ae an Adi nee 10 951 lt Starting and Stoppin gisis inina eA ade nual an ae ae tt wae ees 10 9 2 Using the LCD and Entering Data 10 10 Telemetry and Remote Control 11 11 Monitoring Other SySteMS ccccceeeeeceeee cesses ceeeeeeeaeeeeaeeseeeeesaeeseaeeseaaeseneeeeeaeseeeeeeeneess 11 11 1 Conductivity Probe Interface ooocccccccininicinnccnoccccconnnnncnnnanoccnnnnnn arc nnn cnn rca naar cnn 11 12 Appendix LEDS umi a 12 12 1 RUN LED viii Aa 12 12 2 STOP LEDien o aie a aaa aa 12 123 ALARM LEDin A AA A 12 12 4 Battery LED Cita Aa 12 12 5 CHARGING HED usas ai eine eve 12 12 6 Solenoid LED ii A ee eA 12 12 7 PUMP LED oia A eta ie ae et 12 12 8 Nutrient LED oca nie thie dae a ae ee Re ee 13 12 9 Gate Valve ED gees dd 13 12 10 Remote LED AA eee ti a ae ed 13 12 11 Water LED AAA ee eee 13 12 12 Alarm Relay LED oia take en eit wate nn Soha ad 13 13 Appendix 2 Menu Syste Mitin arti dv eit ni ee aA 14 13 1 Navigating the Men s iii ds 14 13 2 Top Level Menudeo 14 13 3 DEBUG Mehr Ax iota vies Ate aka Adar Awe e ek AE
31. se are set in the CONFIG Menu When the conductivity is above the level set in the COND BLOCK LVL the controller will ignore pulses from the water meter Note that the Conductivity Monitor must be enabled for this to work 6 3 Conductivity Alarm If the conductivity is above the level set in the COND ALARM LVL the controller will trip out and shut down Note that the Conductivity Monitor must be enabled for this to work 6 4 Nutrient Meter Health The nutrient meter produces a thousand or so pulses per litre During the middle of each dose the 0121 looks at the pulses and if the pulses become erratic such that no pulses are received for about 24ms that the system will shut down and report a CHECK NUTRIENT SENSOR alarm 6 5 Double water meter pulse If a second water meter pulse is received from the water meter while the solenoid and pump are enabled ie while the system is dosing then the system will shut down Please note that if a conductivity sensor is used then the water meter is locked out when the conductivity is above the BLOCK threshold setting and so a second water meter pulse in this situation is ignored 7 A Few Points to Bear In Mind If the mixing tube is too short then the urea will not have time to mix with the water and the conductivity will be high It becomes difficult to distinguish between a normal dose and a dose where the pump has run too long If the mixing tube is too long then the conductivity pulse will not be mu
32. sed and the solar panel is connected to the battery and therefore charging it The unit measures the battery voltage and switches OFF when the voltage reaches 13 8V ON means the battery is being charged at the full rate FLASHING means the battery is being float charged at 13 8V 12 6 Solenoid LED GREEN On indicates that the Solenoid is energized This LED will light momentarily before the pump starts 12 7Pump LED GREEN On indicates that 12V is being supplied to the Pump Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 13 12 8Nutrient LED GREEN On indicates that the signal from the nutrient meter pin 14 is high This LED will flash as nutrient is injected 12 9Gate Valve LED GREEN On indicates that the Gate Valve is OPEN 12 10Remote LED GREEN On indicates that Power Relay is energised That is pin 18 is connected to pin 20 This relay is energised whenever the unit is in RUN mode and it is de energised when the unit is in STOP mode or ALARM Mode 12 11 Water LED GREEN On indicates that the reed switch in the main water meter is closed This LED normally flashes as the water flows through the meter Atthe same time the slave relay connected between pins 18 and 19 is closed 12 12Alarm Relay LED RED ON means that the Alarm Relay is ENERGISED and that pin 25 is connected to Pin 27 This would normally be used
33. the config menu You know when you are in the config menu because there is a in the top right of the display If you are not changing a value press the ESC key to return to the main menu indicates config menu DOSING MODE it NUTRIENT METER SET POINT 1 00 5 SET ALARM LEV dg EE WATER CAL Ll Pu lse Trig This menu is used to select between the two fundamental control modes These two modes are Timer Mode and Nutrient Meter Feedback Mode See section 5 for a detailed description of the two modes The SET POINT display is used to set the target dose If the DOSING MODE is set to TIMER MODE then the SET POINT is in seconds If the DOSING MODE is set to NUTRIENT METER then the set point is in percent This display is used to enter the level at which the unit will trip out The display is dependant on the setting of the DOSING MODE If the DOSING MODE is set to NUTRIENT METER then the alarm is in percent If the dosing mode is set to TIMER MODE then this menu is not visible and the system will trip out if the pup runs for more than 3 seconds Note that Irrespective of the setting of this display the unit will trip out if the pump runs for longer than 3 seconds when dosing or 15 seconds when priming This menu is used to set the number of water meter pulses that are required to trigger a dose Normally this is set to 1 and a water meter that provides one pulse per 10 litres is
34. tridose Controller with Conductivity Probe Page 32 17 Tone Pulse Telemetry The 0121 can be connected to a two way radio or other device to provide notification of an alarm condition When the unit is in alarm mode the alarm relay is activated Note that the operation of the alarm relay can be set to either pulse or latching mode To transmit a tone sequence the mode of operation of the alarm relay must be set to PULSE The 12V power for the radio can be connected directly from the battery To conserve power the radio power can be switched using the POWER relay on pins 18 19 and 20 When the 0121 is in the alarm state the tone sequence is generated on pin 28 Once per minute the alarm relay is closed for about 5 seconds across pins 25 and 27 This keys on the transmitter and transmits the tone sequence Radios vary in the audio level required The level out of the 0121 is fairly high There is a 100k resistor in series with pin 28 inside the 0121 Resistor R1 is selected to reduce the audio level to that required by the particular radio used The smaller the value of R1 the lower the volume R1 should ideally be soldered inside the microphone connector but it could also be inserted in the terminal block on the 0121 between pins 23 and 24 Tel 07 3848 5290 Fax 07 3848 5231 kt mM Pastoral 8 Feedlot Systems Nutridose Controller Monitor 17 Railway Road FAIRFIELD 4103 Lightning Protection BO OJO
35. w meter can become calcified This initially shows up as intermittent operation with the occasional pump on too long alarm This means that too much nutrient has been dosed Whenever the system trips out the user should fully investigate the reason for the trip out Do not simply press the go button 5 2 Timer Mode In the timer mode the unit runs the pump for the same constant time duration for each injection This has the advantage of simplicity and reliability however careful attention must be paid to ensure that the water pressure remains constant otherwise an under or overdose situation can occur Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 8 6 Built in Safety and Monitoring functions The 0121 controller has a number of built in interlocks to try to limit the damage in the event of failure of components in the system However these interlocks should not be used to compensate for poor system performance or as an excuse for a lack of maintenance 6 1 Maximum Pump On Time Irrespective of the other settings the maximum time that the pump can be switched on is approximately 3 seconds when dosing and 15 seconds when the prime button is held down This is hard coded into the software and the user can not disable it 6 2 Conductivity Water Meter Lock out There are two thresholds that the user can enter that relate to conductivity The
36. water flows through the mixing tube the dose mixes with the water so that a short time later the conductivity begins to rise When the conductivity is above the warning threshold the system locks out the water meter so that it can not get re triggered As the water continues to flow the conductivity increases until it reaches a maximum and then dies away When the conductivity falls below the warning threshold then the system is re armed and will be triggered by a water meter pulse If the dosing mixture is too strong or if the pump has run too long such that the maximum conductivity level crosses the alarm threshold then the system shuts down Syndetic PTY LTD 101 Hyde Rd YERONGA Queensland Australia www syndetic com au M 0121 Manual Nutridose Controller with Conductivity Probe Page 7 5 Control Modes The 0121 controller can operate in one of two fundamental modes 5 1 Nutrient Meter Dosing Mode This is a dynamic feedback control mode In this mode the actual dose is measured on every dose via the nutrient flow meter The time that the pump is on is then adjusted to ensure that the correct dose is injected each time This mode is useful when the Nutridose is connected to a manifold that distributes water to several paddocks in a way where the back pressure changes from day to day A risk with this mode is that if the Nutrient flow meter becomes faulty then the system can over dose In some water supply situations the nutrient flo
Download Pdf Manuals
Related Search