Radio-Master Series User Guide

Radio-Master User Guide Radio-Master Series User Guide Radio-Master User Guide Introduction Thankyou for purchasing a Radio-Master series transceiver module. The Radio-Master range of transceiver modules are designed and manufactured in Australia to seamlessly integrate and complement the Micro-Master range of controllers. The Radio-Master transceiver modules incorporate some important features you should be aware of before operation. These features are listed below. No compromise data protocol to ensure reliable communications Low operating power – Solar Powered Employs Spread Spectrum technology with 15 channels to reduce probability of interference No telemetry licence required Influenced less by building structures, hills and valleys when compared to UHF Factory assigned unique radio identification numbers Up to 5km single hop range. 10km with repeater On-line integrity checking of radio parameters Includes exclusive Posi-Sense feature for solenoid fault detection and reporting of Baccara 2 wire Latching Solenoids and Bermad S985 Latching Solenoids Manual Valve Operation at Front Panel via four momentary action buttons Sealed Lead Acid 12 Volt backup battery Please review this manual before installing and operating the Radio-Master transceiver modules. 2 Radio-Master User Guide CONTENTS Page Chapter 1 1.1 1.2 1.3 1.4 1.5 1.6 Concepts of the Radio-Master Series Controllers.......................................... 4 Overview and Advantages............................................................................................ 4 Power Output Management.......................................................................................... 4 Why VHF and not UHF................................................................................................. 4 Range ........................................................................................................................... 5 Why can Radio-Master transmit over this Range with just 100mW of power? ............ 5 Radio Network and Valve Condition Reporting ............................................................ 5 What is a Radio-Master Radio Network ........................................................... 6 Chapter 2 2.1 Radio-Master Radio Network Components.................................................................. 6 2.1.1 Central Transceiver – RM100.............................................................................. 6 2.1.2 Slave Transceiver – RM200 ................................................................................ 6 2.1.3 Valve Module – RM400........................................................................................ 7 2.2 Typical Site Layout ....................................................................................................... 8 2.3 Network Components at the Central ............................................................................ 8 2.4 Network Components at the Field Controller. .............................................................. 9 2.5 Network Components at the Field Node. ..................................................................... 9 Chapter 3 3.1 3.2 3.3 3.4 4.1 4.2 A1.1 A1.2 A1.3 A1.4 A1.5 A1.6 A1.7 A1.8 A1.9 A2.1 A2.2 A2.3 A2.4 A3.1 A3.2 A3.3 A3.4 A3.5 RM400 Operation ............................................................................................. 11 Power On Operation................................................................................................... 11 Manual Valve Operation ............................................................................................. 11 Radio-Master Transceiver Status ............................................................................... 11 Posi-Sense ................................................................................................................. 11 Familiarisation with the Controller................................................................. 13 Interfacing the Radio Master system with a Micro-Master Controller....................... 13 Enable Radio Node outputs........................................................................................ 13 RM100 Installation ...................................................................................................... 15 RM200 Installation ........................................................ 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RM400 Installation ...................................................................................................... 17 Solar Panel Mounting Bracket Installation.................................................................. 18 Aerial Installation ........................................................................................................ 20 Connecting Solar Panel Cable ................................................................................... 20 Powering the RM400 from the RM101 Plug Pack...................................................... 20 Connecting Valve Wire ............................................................................................... 21 Replacing Standby Battery ......................................................................................... 21 Solar Panels ............................................................................................................... 23 Start of Season Maintenance ..................................................................................... 23 End of Season Maintenance ...................................................................................... 23 Storage Requirements................................................................................................ 23 Radio Specifications ................................................................................................... 24 Common Specifications.............................................................................................. 24 RM100 Specifications................................................................................................. 24 RM200 Specifications................................................................................................. 24 RM400 Specifications................................................................................................. 24 Chapter 4 Appendix 1 Installation Instructions .................................................................................. 15 Appendix 2 Preventative Maintenance............................................................................... 23 Appendix 3 Specifications................................................................................................... 24 Appendix 4 Fault Isolation................................................................................................... 26 3 Radio-Master User Guide Chapter 1 Concepts of the Radio-Master Series Controllers 1.1 Overview and Advantages The Radio-Master VHF Spread Spectrum Data Transceiver range has been specifically designed for the Micro-Master range of controllers. No compromise has been made with the data protocol to ensure reliable communications with the lowest operating power. To achieve this, the data transceiver employs Spread Spectrum technology. This allows the radio to achieve the same range as fixed frequency transceivers using up to 2 watts of RF power. The transceiver achieves this by frequency hopping between a choice of 15 for communications. For each and every transmission the radio chooses the quietest channel for communication and uses that channel. The chances of pump or filter motors or other equipment causing interference to the communication is reduced. The transceiver operates at a low power for communications to manage the frequency spectrum and reduce conflict with other units within the network. The Radio-Master Data Transceivers use a current generation range of micro-controllers meaning that the latest design and development tools can be used and supply problems are eliminated. Each system is factory assigned a unique radio identification number so that no communication conflict can occur between adjoining properties and the possibility of erroneous valve activation is eliminated. Will report back to the Micro-Master controller any malfunction in solenoid actuator movement. 1.2 Power Output Management The transceiver will automatically operate at a lower power for near communications to manage the frequency spectrum and reduce conflict with other units within the Network. Each system is factory assigned a network number so that no communication conflict occurs between adjoining properties. 1.3 Why VHF and not UHF VHF is influenced less by building structures, hills and valleys when compared to UHF. By operating in a VHF free-to-air broadcasting section of the radio spectrum, no telemetry licence required. Sensitivity has been designed to limit the desensitising effect of out-of-band signals. 4 Radio-Master User Guide 1.4 Range The operating range of a transceiver depends on the antenna, height of the antenna above ground, line of sight, and obstructions between transmit and receive sites. With the transmit antenna located on a 6 meter mast, and receive antenna mounted clear of any foliage, up to 5km single hop range is possible. With the ability of any transceiver in the system to act as a repeater this range can be increased up to 10km for other more distant transceivers. 1.5 Why can Radio-Master transmit over this Range with just 100mW of power? No compromise has been made with the data protocol to ensure reliable communications with the lowest operating power. With conventional single fixed frequency radio transceivers, the main limitation to range is fading. Normally a figure of 20 – 25db loss must be considered when designing a fixed frequency radio. This equates to approx. 100 times more power than is required to allow for fading. Fading occurs during normal operation due to reflections and changes in atmospheric conditions. With Radio-Master the correct frequency is selected where fading is at a minimum. The Radio-Master transceiver will then reduce the power down from 100mW until the optimum power for the transmission of the data is achieved. This prevents spectrum pollution and the network will operate with optimum power between all Transceivers in the network. With frequency hopping, the radio can operate at a lower power and can therefore operate with a smaller solar panel. 1.6 Radio Network and Valve Condition Reporting The Radio-Master radio network tests the on-line integrity of all radios and reports the results to the central log. These parameters include • • • Field Strength (noise and signal levels). Power supply and standby battery condition. Ambient temperature. The Radio-Master Valve Module will examine the switch on and switch off characteristics of the latching solenoid valves at the radio nodes and report a faulty coil. 5 Radio-Master User Guide Chapter 2 What is a Radio-Master Radio Network 2.1 Radio-Master Radio Network Components The Radio-Master radio network consists of three main components complementing the Micro-Master range of controllers. 2.1.1 Central Transceiver – RM100 The RM100 Central Transceiver is connected to the central personal computer and is used to transmit to all RM200 Slave Transceivers in the field. The RM100 will communicate with radios within its own network and can be a repeater for any other radio within the network. If so, it will receive the data on one frequency and re-transmit the message on the next quietest channel with the best signal to noise ratio. The RM100 is fitted with an internal 12volt 2.0 AH battery. This will provide power for approximately three days in the event of a power failure. If a power outage is expected to last for longer than three days, the RM100 should be switched off for the duration of the power outage. Connection to the RM100 is via the RS232 serial port of the personal computer. 2.1.2 Slave Transceiver – RM200 The RM200 Slave Transceiver is connected to a Micro-Master 4000 or 4500 controller and is used to communicate back to the central personal computer via the RM100 Central Transceiver and send commands to the RM400 Valve Modules to operate field valves. Up to 5 Micro-Master controllers can be connected to the same Radio-Master RM200 Slave Transceiver using the RS485 interface of the Micro-Master controllers. The RM200 can be a repeater for any other Radio-Master Transceiver within the network. The RM200 is fitted with an internal 12volt 2.0 AH battery. This will provide power for approximately three days in the event of a power failure. If a power outage is expected to last for longer than three days, the RM200 should be switched off for the duration of the power outage. Connection to the RM200 is via a RS485 cable to the red and black RS485 connections on the 6 Radio-Master User Guide Micro-Master 4000 or 4500 controllers. 2.1.3 Valve Module – RM400 The RM400 Valve Module is a four output field module situated in the field at the valve site. It is commanded by Micro-Master 4000 or 4500 controllers via a RM200 Slave Transceiver to switch up to 4 valve outputs. The RM400 can be powered from a Solar Panel or 12 volt plug-pack. The RM400 module is fitted with an internal 12volt 2.0 AH standby battery. The combination of low power transmit and Solar Panel enables continuous reliable operation for up to 5 days under heavy cloud. Internal battery backup provides power for up to 5 days without sun. The RM400 will automatically cycle the power off if the battery voltage becomes too low to prevent battery damage. When the battery is recharged, the RM400 will reapply power. The RM400 can be a repeater for any other Radio Master Transceiver within the network. The RM400 supports 12 volt, two wire latching solenoids. Each output can be switched on and off at the node with a push button switch. The RS485 expansion link is included for future expansion. RM400 modules include on-line integrity checking of Field Strength, Input Voltage, Ambient Temperature and Battery condition. These conditions are reported back to the Micro-Master 4000 or 4500 controller and are displayed when the Manual Station feature of the MicroMaster 4000 or 4500 controller is activated. The RM400 also includes the exclusive Posi-Sense feature for solenoid fault detection and reporting. The Posi-Sense feature of the RM400 senses and discriminates the switch-on and switch-off characteristics and will automatically retry if the solenoid actuator fails to move. The RM400 will report any malfunction in solenoid actuator movement back to the Micro-Master controller. Posi-Sense can correctly discriminate the characteristics of Baccara 2 wire Latch Solenoid operators and Bermad S985 Latch Solenoids. The connection of other latching solenoids may result in incorrect reporting of solenoid fault conditions. Posi-Sense can be disabled or enabled at the RM400 front panel without disassembly of the RM400. 7 Radio-Master User Guide 2.2 Typical Site Layout A typical layout for a Radio-Master network is shown below. RM100 at Central Computer RM200 at the field controller RM400 nodes to connect to field Valves (2 wire latching) 2.3 Network Components at the Central 8 Radio-Master User Guide IBM Compatible Personal Computer Micro-Master 4000 Software – part number CMM4000200 Radio-Master Central Transceiver part number RM100. This unit will connect directly to a serial connector of the PC. Supplied with a 1.5 metre RS232 communication cable. Radio-Master part number RM101 This is a 12 Volt 0.3 Amp Plug-pack. A RM101 is supplied with each RM100. Radio-Master part number RM105 Low wind resistance lightweight stainless steel omnidirectional antenna with 5 metre cable. Radio-Master part number RM110 10 metre Low loss coaxial antenna extension cable. Radio-Master part number RM120 20 metre Low loss coaxial antenna extension cable. Radio-Master part number RM130 30 metre Low loss coaxial antenna extension cable. Radio-Master part number RM102 12 volt 2.0 AH rechargeable lead acid standby battery 2.4 Network Components at the Field Controller. Micro-Master 4000 – 32 station part number 1013524 Micro-Master 4000 – 16 station part number 1013522 Micro-Master 4000 Communication Chip – part number CMM4000201 Note: Micro-Master controllers manufactured prior to May 1999 are not fitted for RS485 communications. If your Micro-Master controller was manufactured prior to May 1999, contact your local Toro dealer for further information. Radio-Master Slave Transceiver part number RM200. This unit will connect directly to a serial connector of the Micro-Master controller. Supplied with a 1.5 metre RS485 communication cable. Up to 5 additional field controllers at this site can also connect to the same radio with the Micro-Master RS485 interface. (Distance up to 1Km with screened communication cable.) Radio-Master part number RM101 This is a 12 Volt 0.3 Amp Plug-pack. Radio-Master part number RM105 Low wind resistance lightweight stainless steel omnidirectional antenna with 5 metre cable. Radio-Master part number RM110 10 metre Low loss coaxial antenna extension cable. Radio-Master part number RM120 20 metre Low loss coaxial antenna extension cable. Radio-Master part number RM130 30 metre Low loss coaxial antenna extension cable. Radio-Master part number RM102 1.2 AH rechargeable lead acid standby battery 2.5 Network Components at the Field Node. Radio-Master Valve Module part number RM-400. Solar powered 4 valve 2 wire latching output. Radio-Master part number RM101 240 volt to 12 Volt 0.3 Amp Plug-pack. Radio-Master part number RM103 12 volt 4 Watt Solar Panel and Aerial Mounting Kit. Hardware is provided to mount the unit onto readily available 1” or 2” water pipe, providing an easy installation option. Radio-Master part number RM105 Low wind resistance lightweight stainless steel omnidirectional antenna with 5 metre cable. Radio-Master part number RM106 RM400 Mounting Plate. This plate allows easy mounting of the RM400 to round posts. It also provides limited protection from the weather for extreme environments. Radio-Master part number RM110 10 metre coaxial antenna extension cable. Radio-Master part number RM120 20 metre coaxial antenna extension cable. Radio-Master part number RM130 30 metre coaxial antenna extension cable. Radio-Master part number RM102 1.2 AH rechargeable lead acid standby battery 9 Radio-Master User Guide Radio-Master part number RM101 240 volt to 12 Volt 0.3 Amp Plug-pack. Radio-Master part number RM103 12 volt 4 Watt Solar Panel and Aerial Mounting Kit. Radio-Master part number RM105 Stainless Steel Omni-directional Antenna. Radio-Master part number RM106 RM400 Mounting Plate. This plate allows easy mounting of the RM400 to round posts. It also provides limited protection from the weather for extreme environments. Radio-Master part number RM102 1.2 AH rechargeable lead acid standby battery 10 Radio-Master User Guide Chapter 3 RM400 Operation 3.1 Power On Operation The RM400 performs several power up tests and initialisation routines. At power up the Pwr/Rx/Tx lights should flash quickly for approximately 10 seconds. The Pwr light will then flash for ¼ of a second every two seconds. This indicates that the RM400 is in low-power sleep mode. The ‘On’ and ‘Off’ lights also flash in a sequence determined by the RM400 configuration. If Posi-Sense is enabled, the RM400 will flash the ‘On’ LED four times. If Posi-Sense is disabled, the RM400 will flash the ‘Off’ LED four times. The RM400 will then turn off each of the valves in turn to complete the system initialisation. The RM400 contains a continuous built in health monitoring system. If this circuitry detects a anomalous condition it will attempt to correct the condition by resetting the RM400 controller. If this occurs, the RM400 will not reinitialise the valves. 3.2 Manual Valve Operation The RM400 contains four momentary action push-on push-off Manual Valve Operation buttons. These are accessible when the RM400 front panel is removed. The buttons are labelled 1 to 4 and correspond to each of the 4 valve outputs. When a button is pushed the RM400 will turn on or off the appropriate valve depending on the current state of the valve. When the RM400 turns on a valve it will turn on the Green ‘On’ LED. This LED will remain lit for as long as the button is held pushed. During periods of bright sunshine, this allows the operator sufficient time to view the LED if required. The RM400 will apply power to the valve only for the required time. If the same button is released and pressed again the RM400 will turn off the appropriate valve and turn on the Red ‘Off’ LED. Similarly, this LED will remain lit for as long as the button is held pushed. 3.3 Radio-Master Transceiver Status The RM400 radio has three LEDs that indicate the current state of the Radio-Master node. The Radio-Master transceivers are bi-directional. This means that both the calling and called transceivers exchange information during communication. This ensures high reliability communications with the lowest operating power. The Yellow Receive (Rx) LED will be lit when the Radio-Master is receiving data and the Red transmit (Tx) LED will be lit when the Radio-Master is transmitting data. The Green Power (Pwr) LED indicates that power is applied to the RM400. In low power Idle Mode, the LED flashes for ¼ second every two seconds. When any Radio-Master transceiver in the Radio-Master network has been accessed, all Radio-Master transceivers will enter Alert Mode operation. During this mode of operation, Radio-Master transceivers are able to quickly synchronise with a calling Radio-Master transceiver to reduce the amount of time required to turn on a valve. The Radio-Master transceiver remains in Alert Mode for 30 seconds after a connection has finished before it reverts to the low power Idle Mode. This time allows a typical irrigation sequence to turn off the current valve before the next valve is turned on. When communications is initiated, the calling Radio-Master transceiver will transmit continuously for up to 2.5 seconds to establish a connection to the called Radio-Master. Once the connection has been established, the Tx and Rx LEDs will alternately flash whilst the RM400 carries out the valve actuation process. Once the RM400 has completed the valve actuation it reports the results back to the calling Radio-Master transceiver. 3.4 Posi-Sense 11 Radio-Master User Guide The RM400 Posi-Sense feature detects and reports for solenoid faults. Posi-Sense functions by sensing and discriminating the switch-on and switch-off power characteristics of the solenoid valve. The RM400 will report any malfunction in solenoid actuator movement back to the Micro-Master controller. Posi-Sense can correctly discriminate the characteristics of Baccara 2 wire Latch Solenoid operators and Bermad S985 Latching solenoids. The connection of other latching solenoids may result in incorrect reporting of solenoid fault conditions. Toro recommends the use of Bermad S985 latching solenoids. Posi-Sense can be disabled or enabled at the RM400. If the Manual Valve 1 button is held pressed while the unit is powered on, the RM400 will enable the Posi-Sense valve actuation circuitry. The RM400 will flash the ‘On’ LED four times or more if the button is held pressed. If the Manual Valve 2 button is held pressed while the unit is powered on, the RM400 will disable the Posi-Sense valve actuation circuitry. The RM400 will flash the ‘Off’ LED four times or more if the button is held pressed. The setting is stored in non-volatile memory. The operation of Posi-Sense requires the RM400 to be configured according to the type of Latching Solenoid connected. The RM400 is factory set for Bermad S985 Latching Solenoids. If the Manual Valve 3 button is held pressed while the unit is powered on, the RM400 will enable the Posi-Sense valve actuation circuitry for Bermad solenoids. If the Manual Valve 4 button is held pressed while the unit is powered on, the RM400 will enable the Posi-Sense valve actuation circuitry for Baccara solenoids. The type of valve selected is indicated by the flashing rate of the four flashes when the RM400 is turned on with no buttons pressed. A RM400 configured for Bermad solenoids flashes at a short ¼ second rate. A RM400 configured for Baccara solenoids will flash at a ¾ second rate. 12 Radio-Master User Guide Chapter 4 Familiarisation with the Controller 4.1 Interfacing the Radio Master system with a Micro-Master Controller The RM400 Radio-Master Valve Modules can be connected into the controller by simply entering the RM400 address and output number in the Radio Node Database. Each Radio-Master node (RM100, RM200 and RM400) is delivered with a 5 digit unique address (0 to 65500). This address will be found on the LHS of the connector block in the RM400. The Valve outputs of each RM400 are numbered 1 to 4. Connection of the Radio-Master Valve output to the Micro-Master controller is entered from this screen or can be entered directly at the Micro-Master controller under the Setup Menu. Example 1 Link station 2 of the Micro-Master controller to a RM400 (address 1047), to output number 2 (up to 4 valve outputs for each radio node). In this example, the radio communications for this RM400 node requires a repeater (11223), which can be any other radio in the network to enable reliable communications to more distant or difficult locations. 4.2 Enable Radio Node outputs. The Link to the Radio-Master Valve Modules for each Micro-Mastercontroller can be globally enabled or disabled by clicking the mouse on the following checkbox. When the checkbox is ticked, all Radio Control Valves will be enabled. 13 Radio-Master User Guide When the OK button is clicked, this data is down loaded to the Micro-Master controller. During irrigation, when Station 2 requires irrigation, the controller will make radio contact with the Repeater (11223) to pass on the command to Radio Node (address 1047) and turn on Valve station number 2. After confirmation from the Posi-Sense valve actuation circuitry, the Radio Master node will communicate back to the Micro-Master controller to confirm operation. If the RM400 Posi-Sense valve activation circuitry detects a valve failure, this failure is stored in the controller and transmitted back to the central to be stored in the log. 14 Radio-Master User Guide Appendix 1 Installation Instructions A1.1 RM100 Installation NOTE: It is important for correct and continued reliable operation of the RM100 that cables and wires are not be subjected to deformation or damage during installation or normal use. During installation, ensure that cables and wires are not positioned or routed such that deformation of the cable or wires could occur. Routing of the antenna cable should not result in a bend radius of less than 75mm. Using appropriate fasteners, attach or position the RM100 in close proximity to the central PC. The RM100 is supplied with a 1.5m RS232 cable for connection to the central PC. Connect one end of the RS232 cable to the 9 pin connector on the bottom edge of the RM100 as shown. Connect the plug pack connector to the socket on the bottom edge of the RM100. Plug the RM101 plug pack into an available 240Vac wall socket as shown above. Connect the antenna cable to the coaxial connector on the bottom edge of the RM100 as shown above. The other end of RS232 cable will need to be connected to a spare RS232 serial port of the PC. If you need to move the PC in order to gain access to the serial port connector of the PC, first ensure the PC is powered off. Ensuring the PC is powered off before moving the PC prevents inadvertent shock damage to the PC hard drives. Connect the remaining end of the RS232 serial cable to a spare RS232 serial port on the PC. Power on the PC. 15 Radio-Master User Guide Remove the front cover of the RM100 and turn on the RM100. The Pwr/Rx/Tx lights should flash momentarily. The Pwr light will then flash for ¼ of a second every second. The RM100 will perform internal consistency checks for approximately 10 seconds. The RM100 is now ready for operation. A1.2 RM200 Installation NOTE: It is important for correct and continued reliable operation of the RM200 that cables and wires are not be subjected to deformation or damage during installation or normal use. During installation, ensure that cables and wires are not positioned or routed such that deformation of the cable or wires could occur. Routing of the antenna cable should not result in a bend radius of less than 75mm. Using appropriate fasteners, attach the RM200 in close proximity to the Micro-Master 4000 or 4500 controller. NOTE: If mounting the RM200 to a sheet metal wall, it is essential to mount timber mounts to the metal wall first and then mount the RM200 to the timber. This prevents high temperatures being conducted to the RM200. The RM200 is supplied with 1.5m of attached RS485 cable for connection to the MicroMaster controller. Pass the RS485 cable through the large hole at the bottom centre of the controller case. Strip the red, black and green wires of the cable. Insert the RED wire under the screw labelled Red on the terminal block. Insert the BLACK wire under the screw labelled Black on the terminal block. Insert the GREEN wire under the screw labelled Gnd on the terminal block. 16 Radio-Master User Guide Connect the plug pack connector to the socket on the bottom edge of the RM200. Plug the RM101 plug pack into an available 240Vac wall socket. Connect the antenna cable to the coaxial connector on the bottom edge of the RM200. Remove the front cover of the RM200 and turn on the RM200. The Pwr/Rx/Tx lights should flash momentarily. The Pwr light will then flash for ¼ of a second every second. The RM200 will perform internal consistency checks for approximately 10 seconds. The RM200 is now ready for operation. Configure the Micro-Master Controller for Radio-Master operation Remove power from the Micro-Master controller, and remove the Micro-Master controller panel from the enclosure. Set the communication configuration plugs to S S on the Micro-Master controller panel for RS485 communications. These plugs are located on the front panel circuit board on the right hand side of the Micro-Master controller panel. Replace the Micro-Master controller panel into the enclosure and apply power. Press SETUP until RADIO 3 is displayed. Press key 3 to set the controller to communicate by Radio-Master protocol. The Micro-Master controller is now set up to communicate with Radio-Master protocol. Note: Micro-Master controllers manufactured prior to May 1999 are not fitted for RS485 communications. If your Micro-Master controller was manufactured prior to May 1999, contact your local Toro dealer for further information. A1.3 RM400 Installation NOTE: It is important for correct and continued reliable operation of the RM400 that cables and wires are not be subjected to deformation or damage during installation or normal use. During installation, ensure that cables and wires are not positioned or routed such that deformation of the cable or wires could occur. Routing of the antenna cable should not result in a bend radius of less than 75mm. Using appropriate fasteners, attach the Module Mounting Plate in the desired position using the two ¼” holes located at the top and bottom of the Module Mounting Plate. Using the 3/16” bolts and nuts attach the RM400 to the Module Mounting Plate and tighten. 17 Radio-Master User Guide Connect the antenna cable to the coaxial connector on the bottom edge of the RM400. Route the antenna cable such that a Rain drip loop is formed. The apex of the loop should hang below the bottom edge of the RM400 case. Connect the Solar Panel power leads and Valve wires as described in A1.6 Connecting Solar Panel Cable and A1.8 Connecting Valve Wire. Remove the front cover of the RM400. Turn on the RM400. The Pwr/Rx/Tx lights should flash quickly for approximately 10 seconds. The Pwr light will then flash for ¼ of a second every two seconds. This indicates that the RM400 is in low-power sleep mode. The ‘On’ and ‘Off’ lights will flash in a sequence determined by the RM400 setup. This is described further in Chapter 3 RM400 operation. When the Solar Panel power leads and all Valve wiring has been connected the cable gland nuts should be checked for gaps. To prevent insect infestation, any gaps should be eliminated, by tightening the cable glands securely, or filling the gaps with a suitable allweather sealant. A1.4 Solar Panel Mounting Bracket Installation The specially designed Solar Panel Mounting Panel contains provision for using 1” or 2” water pipe as the standard support mast structure. The panel includes cut-outs for mounting the radio antenna. All hardware required to assemble the Solar Panel Mounting Panel is provided. The versatile mounting arrangements allow for fixing to other support mast materials. 18 Radio-Master User Guide The Solar Panel Mounting Plate has been designed to maximise the average available solar power whilst reducing wind resistance and providing ease of assembly. The angle of the Solar Panel has been optimised for locations near the latitude of Sydney, Adelaide, and Perth. The Solar Panel Mounting Plate kit is supplied with 4 saddle clamps. Both 2” and 1” water pipe saddle clamps are supplied to allow several mounting options. Only two saddle clamps are required to mount the Solar Panel Mounting Plate. Attach the Solar Panel Mounting plate to the mast using two saddle clamps and 3/16” bolts and nuts. Orientate the Solar Panel Mounting Plate so that the dark face of the Solar Panel is facing the direction of the midday sun. This is approximately North and maximises the Solar Panel irradiation. Tighten the 3/16” nuts. Route the Solar Panel power cable and antenna cable to the RM400. Secure the cables using cable ties or other appropriate means. 19 Radio-Master User Guide A1.5 Aerial Installation Note: Depending on the particular installation environment it may be easier to install the whip antenna prior to mounting the Solar Panel assembly onto the mast. Loosen the nut on the base of the antenna and slide the antenna into the slot located on the top edge of the Solar Panel Mounting Plate. Retighten the nut on the base of the antenna. A1.6 Connecting Solar Panel Cable Loosen the left hand cable gland nut and insert the Solar Panel power wires. Tighten the cable gland nut. Strip ¼” of insulation from the Solar Panel wires. Connect the red Solar Panel wire to the Connector Block SP position labelled ”+” and connect the blue or black Solar Panel wire to the Connector Block SP position labelled “-“. A1.7 Powering the RM400 from the RM101 Plug Pack Ensure the RM101 Plug Pack is not plugged into the 240V mains wall socket. Remove the connector from the 2.1mm plug from RM101 Plug Pack cable. Loosen the left hand cable gland nut and insert the plug pack wires. Tighten the cable gland nut. 20 Radio-Master User Guide Separate the plug pack wire into the two conductors and strip ¼” of insulation from each wire. Connect the wire with the white stripe to the Connector Block SP position labelled ”+” and connect the other wire to the Connector Block SP position labelled “-“. Plug the RM01 Plug Pack into a 240V mains wall socket and switch on. Using a voltmeter on at least a 20V range, confirm that a nominal 12V is present at the Connector Black position SP. A1.8 Connecting Valve Wire The RM400 is designed for 2 wire solenoid operation; 12V is momentarily applied across the connector block positions labelled “L” and “U” for each valve when commanded on or off by a Micro-Master controller. Loosen an appropriate cable gland nut and insert the solenoid wires. Tighten the cable gland nut. Strip ¼” of insulation from the solenoid wires. Connect the solenoid latch wire to the to the Connector Block positions marked “L” for the appropriate valve number. For a Bermad S975 solenoid the Latch Wire is White. For a Baccara 2 wire latching solenoid the Latch wire is Green. Connect the solenoid unlatch wire to the to the Connector Block positions marked “U” for the appropriate valve number as shown in the previous picture. For a Bermad S975 solenoid the Unlatch Wire is Red. The Black wire is unused. For a Baccara 2 wire latching solenoid the Unlatch wire is Black. A1.9 Replacing Standby Battery Remove the cover. Remove and set aside the four philips head screws from the front panel. Carefully lift out the front panel from the case. Disconnect the radio antenna cable from the connector on the front panel and lay the front panel to one side. The battery is attached to the box using two strips of Velcro. Note the orientation of the battery in the case before removing the battery. Remove the battery from the case. Remove the red and black wires from the battery. Connect the red wire to the +ve terminal of the new battery. Connect the black wire to the –ve terminal of the battery. 21 Radio-Master User Guide Align the battery in the case with the same orientation as noted above and push the battery into position, ensuring the Velcro is holding the battery. Reconnect the radio antenna cable to the connector on the front panel. Ensuring that wires do not become trapped between the front panel and the mounting posts, align the front panel with the case. Replace the four philips head screws and tighten. 22 Radio-Master User Guide Appendix 2 Preventative Maintenance A2.1 Solar Panels The RM105 Solar Panels need a periodical cleaning to remove any build up of dust or other matter. How often this is required is entirely dependent on local weather conditions but a schedule of once every month during spring, summer and autumn is a minimum. Solar Panels located in areas of extreme dust (alongside dirt roads) may require cleaning more often. Periodical inspection of the Solar Panels is required to check for damage or deterioration. Any cracks caused by physical or environmental damage must be sealed as soon as it is discovered using Selleys Window and Glass Clear Silicone sealant. This should be performed when the cleaning maintenance occurs. A2.2 Start of Season Maintenance If the RM400 has been properly installed there is no requirement for Start of Season of Maintenance apart from turning on the RM400. Inspection of the RM400 cable glands should be done to ensure they have not become loose, and tightened if necessary. Whilst turning on the RM400, the inside of the RM400 should be inspected for insect infestation and removal. Insect infestation could occur through loose cable glands. A2.3 End of Season Maintenance The RM400 Valve Module is specifically designed for low power requirements. It is recommended that the RM400 be left in position and switched off during dormant periods. Even when the RM400 is switched off the Solar Panel will continue to charge the RM400 battery. The RM400 contains over-voltage and under-voltage protection. This will result in a fully charge battery at the beginning of the growing season. Alternatively, the RM400 may be removed to allow access for mechanical harvesters or pruners. If this is performed, and the RM400 is stored out of the sun, the RM400 should be turned off using the switch internal to the unit. Without any sunlight to recharge the batteries the RM400 has a shelf life of 5 months (from a full charge) before becoming fully discharged. A2.4 Storage Requirements The RM400 has a shelf life of 5 months (from a full charge) before becoming fully discharged. The RM400 should be stored in an upright position. The Solar Panel and RM400 case only require appropriate levels of protection from physical damage. There are no other special requirements for storage. 23 Radio-Master User Guide Appendix 3 Specifications A3.1 Radio Specifications Centre Frequency No of Channels Channel Spacing Output Power Input Sensitivity Antenna 151.65 MHz Spread Spectrum 15 100 kHz 100 mW -105 dbm End Fed Dipole, Injection Moulded Coil, Tapered Stainless Steel Radiator 3.0dB bandwidth - 148-174 MHz with 5.0m RG58 cable. A3.2 Common Specifications Battery Type Operating Life Shelf Life Sealed Lead Acid 12 Volt 2 Ampere Hour capacity 5 days without charging (nominal, with fully charged battery) 5 months without charging Ambient Operating Conditions Temperature Humidity Hardware Processor -10° C to 65° C Maximum 95 % non-condensing CMOS Low Power Integrated circuit technology A3.3 RM100 Specifications Hardware Cabinet Dimensions Mass Weather proof to IP55, grey base with clear lid, neoprene gasket seal 150(Width) x 190(Height) x 80(Deep)mm as mounted 60 to 70mm clearance required for wire entry clearance (add to height) 1.3 kg A3.4 RM200 Specifications Hardware Cabinet Dimensions Mass Weather proof to IP55, grey base with grey lid, neoprene gasket seal 150(Width) x 190(Height) x 80(Deep)mm as mounted 60 to 70mm clearance required for wire entry clearance (add to height) 1.3 kg A3.5 RM400 Specifications Hardware Relays Cabinet Dimensions Sealed, high-current Alloy contacts. 1 Solenoid per Valve Output Weather proof to IP55, grey base with grey lid, neoprene gasket seal 210(Width) x 185(Height) x 80(Deep)mm as mounted 60 to 70mm clearance required for wire entry clearance (add to height) Mass 1.7 kg Valve connectors Maximum conductor size 4mm2 or 12 AWG per terminal Recommended Latching Solenoids Baccara 2 wire Latch Solenoid, Geva 75, 2 wire 9-12VDC Latch 24 Radio-Master User Guide part number G75-O-1xxx2 Bermad S985 3 wire latching solenoids Maximum Valve Wiring 3m *Reference to specific products, services or companies in this publication does not imply endorsement or specific recommendation of any product, service or company. 25 Radio-Master User Guide Appendix 4 Fault Isolation A number of tools are required to isolate and remedy Radio-Master faults. For detailed fault isolation, the Radio-Master diagnostic software, a RS232/485 converter or RM100 Central Transceiver and RM105 aerial is required. To measure battery and solar panel and plug pack voltages, a voltmeter capable of measuring up to 30 volts is required. Radio-Master fault isolation is accomplished by eliminating portions of the system. The type of fault reported and the coverage of the fault can indicate the faulty unit. An illustration of the functional areas in a typical Radio-Master installation is given below. Antenna Antenna Antenna Solar Panel RM200 Radio RM200 Repeater Node RM400 Radio RM200 Buffer RM200 Charger RM400 Processor RM400 Charger Micro-Master 4500 Controller Plug Pack Valve Switching Circuit RM400 Antenna Field Wiring RM400 Valve Module Solenoid Coil Typical Site Layout for Fault Isolation If communication can occur from the Micro-Master controller to one or more RM400 transceivers, then the RM200 and associated items can be eliminated from the fault investigation. The following to diagrams describe a sequence of steps to test each individual function shown in the above diagram. Each step requires either the Radio-Master Diagnostic software, the Micro-Master controller or the voltmeter. The Manual Station feature of the Micro-Master 26 Radio-Master User Guide controller can be used to isolate most faults. The Manual Station feature reports the Signal Strength, Battery Voltage and Temperature at the destination node. 27 Radio-Master User Guide Communication Faults on 4000/4500 Yes No Check Radio Addresses in 4000/4500 Check Repeater Addresses in 4000/4500 Plug Pack LED on Communication Problems to all Radios or Individual All Radios Individual Check RM400 Yes No Plug Pack Fault Return for service Check voltage at lug Pack connector? Positive inside Yes RM200 Battery Voltage >10V > 14V <10V Voltage at battery connectors with attery disconnected >13V < 14V One or more RM200 LEDs remain on No < 13V RM200 Charging Fault Return for service Use RM100 via antenna on RM200 Not OK RM200 Fault Return for service Wait for several hours Use RM100 via separate antenna OK OK Recheck Battery Voltage Not OK Battery Fault Return for service RM200 Antenna connected OK and undamaged No Yes Reconnect or return antenna for service Tx and Rx lights flash when commanded No Does the Tx light at the RM200 flash when commanded No LED sequence on RM200 is Red/Yellow/Green 10 times/second Radio is communicating with some missed packets Yes LED sequence on M200 is Red/Yellow 10 times/second Radio is communicating Likely RM200 fault Contact Toro Service LED sequence on RM200 is Red/Green 10 times/second Radio address cannot be reached System Fault Fault Isolation 28 Radio-Master User Guide RM400 does not respond to radio commands Check Battery Voltage OK <10V No RM400 manual operation OK Yes Battery Voltage No Reconnect or replace antenna Tx and Rx lights flash when commanded No Yes RM400 Fault Contact Toro Service No Plug Pack LED on? Disconnect SP wires and check voltage of Solar Panel > Battery Voltage < Battery Voltage Yes Check valve wiring Plug Pack fault Return for service Does the Tx light at the RM200 flash when commanded Yes No < Battery Voltage Check voltage at Plug Pack connector? Positive inside Current at SP input blocks (needs sunlight) >Battery Voltage <10mA Valve resistance 4.5 ohms (nom) Yes Likely RM200 fault Contact Toro Service Low (<10mA) (Plug Pack) Current at SP input blocks (needs sunlight) Solar Panel deterioration No Contact Toro Service No Is this the only RM400 affected Compare with known good valve Not OK > 10mA No < 13V Voltage at battery connectors with no battery connected >13V Yes OK Yes RM400 Charging Fault Return for service Solar Panel fault Return for service Likely RM400 fault Contact Toro Service Wait for several hours RM400 Fault Contact Toro Service Recheck for Battery Voltage Faulty coil or Field Wiring RM400 Fault Isolation 29 Radio-Master User Guide NOTES 31 A business unit of Toro Australia Pty Limited 53 Howards Road Beverley SA 5009 Customer Service Hotline: 13 15 88 Fax No: (08) 8234 2940 2 April, 2002