Western CP600, Operation Manual

Page 1: ...CP600 Pivot Operation Manual POM EN December 2018 ...

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Page 3: ...ions 2 Revolution Times and Water Application 4 Revolution Times and Water Application Charts 6 Sprinklers 7 End Guns Nelson 36 Standard Galvanized Drop Details 37 Standard Flexible Hose Drop Detail 38 Variable Spacing Drop Details 39 Slurry Drops 40 Standard Galvanized Extended Drop Detail 41 Adjustable Drop 42 Section 3 Getting Started Before Your Machine Arrives 2 Slope Considerations 3 Power S...

Page 4: ... Local iControlremote 11 Safety Override 12 Disconnect Switch 13 Section 5 Electrical A Word About Proper Grounding 2 Standard Panel Span Cable Connections 3 Panel Wiring 90239 41_R4 4 Main Panel Parts List 6 Standard Panel Schematic 8 CP JB Intermediate Cam 10142 01 10 End Tower Junction Box w out Auto Reverse and Booster 90017 01 12 Stall Timer Wiring 90016 01 13 Collector Ring Wiring 14 Warning...

Page 5: ...5 POM EN December 2018 CP600 Pivot Operation Manual Section 1 Operation Safety Maintenance ...

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Page 7: ...ICALLY MOVING PARTS FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR POSSIBLE DEATH WARNING HIGH VOLTAGE POTENTIAL FOR ELECTROCUTION WARNING STAY CLEAR OF HEAVY MATERIAL BEING LIFTED ABOVE WARNING MACHINE MAY INTERMITTENTLY START OR STOP WARNING BE AWARE OF SURROUNDING POWER LINES WHEN INSTALLING OR TROUBLESHOOTING EQUIPMENT FAILURE TO DO SO COULD CAUSE SE RIOUS INJURY OR POSSIBLE DEATH WARNING ...

Page 8: ...g Out Manufacturer recommends locking the main power disconnect before servicing or troubleshooting electrical components See CAUTION or WARNING Disconnect electrical power prior to servicing or troubleshoot ing components WARNING DO NOT ATTEMPT TO ASSEMBLE OR TROUBLESHOOT MACHIN ERY IF THERE IS POTENTIAL FOR A LIGHTENING STORM COMPONENTS ARE HIGHLY CONDUCTIVE AND SERIOUS INJURY OR POSSIBLE DEATH ...

Page 9: ...er safety limit switch roller is in the middle of the V of the cam Tighten the adjusting nuts After the machine is started final alignment should be performed according to the procedure in maintenance section alignment 6 Voltage Voltage at the pivot panel should be 480V on all three legs of the power lines Note Voltage is dependant upon your location Voltage should not be more than 5 higher or low...

Page 10: ... running in the forward direction and the percent timer set to 75 percent Stand between tower 2 and tower 3 and sight across motors No 2 and 1 to the pivot stand pipe Tower 1 should start when motor 1 appears to be slightly behind and shut off when it appears to be an equal distance ahead of the center of the standpipe When tower 1 is properly aligned stand between towers 3 and 4 and sight across ...

Page 11: ...CP600 Pivot Operation Manual POM EN December 2018 11 Figure 1 7 Section 1 7 Operation Safety Maintenance Machine Alignment ...

Page 12: ... EN December 2018 12 GOOD BAD BAD BAD Rotation Forward Clockwise Desired Bow Too Much Leading Bow Trailing Bow Crooked Total Bow For System is About One Tire Width Figure 1 8 Section 1 8 Operation Safety Maintenance Machine Alignment ...

Page 13: ...CP600 Pivot Operation Manual POM EN December 2018 13 Overhead View of Cam and Safety Switch SafetySwitch Section 1 9 Operation Safety Maintenance Cam and Safety Switch ...

Page 14: ...all new tires to a higher pressure for truck loading requirements Set tire pressure so side wall has slight flex If tire creases increase pressure If tire pressure too low tires will lose bead and damage the tube CAUTION Operating tires below the manufacturers recommended pressure can result in damage to the tire sidewall in addition to voiding your warranty WHEEL BOLTS Check to ensure they are ti...

Page 15: ...ECTRICAL Check all wire connections particularly on starters to ensure they are tight ELECTRICAL Check safety limit switches in tower junction boxes ELECTRICAL Check function of automatic switching devices such as Auto Reverse Auto Stop and End Gun lube as required CONTROL Check junction box cam and bushings Turn cam back and forth several times to ensure there is no binding Section 1 11 Operation...

Page 16: ...input and output shaft seals for leakage Should either the input or out put shaft show excessive leakage the seals should be replaced All replaced seals must be installed with generous amounts of 2 Barium Lithium based grease or use equivalent quality 2 wa ter resistant grease 2 External dust exclusion seals should be used to keep dirt and water out of internal seal lo cations If the external seal...

Page 17: ...bs 38 42 N m 6 All wheel lug nuts should be torqued to 115 120 ft lbs 156 162 N m 7 Remove drain plug located at bottom of gearbox and completely drain gearbox If oil is con taminated or emulsified flush gearbox with a cup of specified oil and let drain completely 8 Replace drain plug and refill gearbox through top fill hole to the proper operating level top of worm gear as shown below After one o...

Page 18: ...AE 85W 140 Sprinkler Lube 1200 Oil capacity is approximately 1 U S Gallon 3 8 Liters C In season final drive gearbox Maintenance Final drive gearboxes should be inspected periodically during the operating season for the follow ing 1 The proper oil level should be maintained at all times 2 Contaminated or emulsified oil should be replaced with fresh oil 3 Input seal drain holes on the final drive g...

Page 19: ...n holes located under the motor can must be kept clear to allow for drain age of accumulated moisture inside the motor if required Do not Western or remove plug 4 The two 2 drain holes located under the end bell must be kept clear to allow drainage of accumulated moisture inside of the junction box 5 Remove drain plug located at bottom of gearbox and completely drain gearbox If oil was contaminate...

Page 20: ...nce Helical gear center drive gearboxes should be inspected periodically during the operating season as follows 1 The proper oil level 1 1 2 45 mm from top of gear case should be maintained at all times 2 Contaminated or emulsified oil should be replaced with fresh oil 3 Input output shaft seals should be inspected for excessive leaks and replaced if neces sary 4 Motor drain holes must be kept cle...

Page 21: ...ith new seals 3 The flange drain hole located under the motor mount flange must be clear Clear the hole with a 12 gauge wire nail or punch by rotating the tool in the hole to loosen and remove dirt 4 All 5 16 18 flange bolts and end cap bolts should be torqued to 13 15 ft lbs 18 0N m 5 To drain gearbox remove drain plug located at bottom of worm gear and bottom of side case cover If oil is contami...

Page 22: ... In season worm gear center drive maintenance 1 Proper oil level mid bull gear should be maintained at all times 2 Contaminated or emulsified oil should be replaced with fresh oil 3 Input and output shaft seals should be inspected for excessive leaks and should be re placed if necessary A Driveline Coupler Maintenance 1 Drive line couplers should be inspected periodically for loose bolts and worn ...

Page 23: ...the pivot must be isolated and rendered inoperative This standard establishes minimum performance requirements for the control of such hazardous energy You must lock the pivot out if you are going to 1 Remove or bypass a guard or other safety device 2 Place any part of your body into an area on the pivot where there is a pinch point 3 Work on the electrical circuitry 4 Obstruct the pivot path whee...

Page 24: ...of the pivot s energy source and determine any related haz ards 2 If the machine or system is operating shut it down by rotating the forward reverse selector switch to the off position 3 On the main control panel turn the main disconnect lever to the off position so the pivot cannot be energized while it is being serviced Drain all water from the system and disen gage any automatic valves If your ...

Page 25: ... is energized and shall include a legend such as the following DO NOT START DO NOT OPEN DO NOT CLOSE DO NOT EN ERGIZE and DO NOT OPERATE Attachment devices for tags shall be non reusable and have a minimum of 50 lb 222 N breaking strength Locks used to lockout machines or equipment shall have a key unique to that lock Using Tags without Locks There are limitations to the tagout system Since tags a...

Page 26: ...ll remove his her lock s or tag s from the multiple lockout tagout device s Restoring the Pivot to Normal Operations 1 After maintenance is complete and the pivot is ready for normal operations check around the area of the pivot to ensure that the field is not obstructed by vehicles and that everyone is clear of the pathways of all pivot towers It is especially important to check the entir length ...

Page 27: ...use a clip on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly Use a safety cage if possible NEVER cut or weld on an inflated tire or rim assembly Heat from welding could cause an increase in pressure and may result in tire explosion Do not attempt to mount a tire if you do not have the proper equipment and experience to perform t...

Page 28: ...tely drained 4 Disconnect poly line tubes from solenoid valves and end gun components to drain water from lines 5 All sprinkler control valves should be in the open position and drained Valve control hoses should be drained Solenoid manifold assembly filters should be cleaned 6 Protect moving parts and bearing surfaces against rust and corrosion by greasing all fittings 7 Sufficient oil should be ...

Page 29: ...CP600 Pivot Operation Manual POM EN December 2018 29 Section 1 25 Operation Safety Maintenance Lube and Oil Charts ...

Page 30: ... The charts listed above are intended to be used as a quick reference Review the sections that pertain to the equipment being serviced or the indi vidual manufacturers warranty for specific details Section 1 26 Operation Safety Maintenance Lube and Oil Charts ...

Page 31: ...CP600 Pivot Operation Manual POM EN December 2018 31 DATE SERVICE PERFORMED Section 1 27 Operation Safety Maintenance Service Log ...

Page 32: ...CP600 Pivot Operation Manual POM EN December 2018 32 DATE SERVICE PERFORMED Section 1 28 Operation Safety Maintenance Service Log ...

Page 33: ...CP600 Pivot Operation Manual POM EN December 2018 33 DATE SERVICE PERFORMED Section 1 29 Operation Safety Maintenance Service Log ...

Page 34: ...CP600 Pivot Operation Manual POM EN December 2018 34 Section 1 30 Operation Safety Maintenance Troubleshooting ...

Page 35: ...CP600 Pivot Operation Manual POM EN December 2018 35 Section 1 31 Operation Safety Maintenance Troubleshooting ...

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Page 41: ...CP600 Pivot Operation Manual POM EN December 2018 41 Section 2 General Information ...

Page 42: ...Operation Manual POM EN December 2018 42 Note For Low Profile Machines subtract 126lbs or 157 15kg For High Profile Machines add 280lbs or 127 01kg Section 2 2 General Information Span Tower Weights and Dimensions ...

Page 43: ...CP600 Pivot Operation Manual POM EN December 2018 43 Section 2 3 General Information Span Tower Weights and Dimensions ...

Page 44: ...CP600 Pivot Operation Manual POM EN December 2018 44 Section 2 4 General Information Revolution Times and Water Application ...

Page 45: ...CP600 Pivot Operation Manual POM EN December 2018 45 Section 2 5 General Information Revolution Times and Water Application ...

Page 46: ...CP600 Pivot Operation Manual POM EN December 2018 46 Section 2 6 General Information Revolution Times and Water Application Charts ...

Page 47: ...CP600 Pivot Operation Manual POM EN December 2018 47 Section 2 7 General Information Sprinklers ...

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Page 76: ...CP600 Pivot Operation Manual POM EN December 2018 76 Section 2 36 General Information End Guns Nelson ...

Page 77: ...CP600 Pivot Operation Manual POM EN December 2018 77 Section 2 37 General Information Standard Galvanized Drop Details ...

Page 78: ...CP600 Pivot Operation Manual POM EN December 2018 78 Section 2 38 General Information Standard Flexible Hose Drop Detail ...

Page 79: ...CP600 Pivot Operation Manual POM EN December 2018 79 Section 2 39 General Information Variable Spacing Drop Details ...

Page 80: ...CP600 Pivot Operation Manual POM EN December 2018 80 Section 2 40 General Information Slurry Drops ...

Page 81: ...CP600 Pivot Operation Manual POM EN December 2018 81 Section 2 41 General Information Standard Galvanized Extended Drop Detail ...

Page 82: ...CP600 Pivot Operation Manual POM EN December 2018 82 Section 2 42 General Information Adjustable Drop ...

Page 83: ...CP600 Pivot Operation Manual POM EN December 2018 83 Section 3 Getting Started ...

Page 84: ...divide the rise of the slope by the horizontal run of the slope as shown in the slope details following For example if a slope rises one foot in ten feet measured horizontally then the slope is 1 10 or 10 Other more obvious considerations may include obstacles such as buildings power poles fences trees rock outcroppings well sites etc Be sure that the machine will adequately clear these before ass...

Page 85: ...sion on an ascending slope Exceeding the slope limitations set forth could create excessive tension and compressive forces in both spans and especially the pivot point Figure 3 Longitudinal Slope Rise a Rise b Run a Run b Slope Figure 3 4a Dips and Ravines In a longitudinal slope situation as shown in Figure 1 6 a the spans are placed in either tension on a descending slope as shown or compression...

Page 86: ...ots in the field If machine recon figuration is chosen be sure to consider the entire field as changing the machine configuration to alleviate one problem may cause another problem somewhere else Lateral movement of a machine on a slope as shown in Figure 1 7 is when more than one tower is on the same type of slope i e ascending or descending Exceeding slope limitations here could move the center ...

Page 87: ...most likely condition to cause actual structural damage since the span is actually being twisted In this situation both slopes should be calculated and added together to determine whether or not slope limitations have been exceeded For example if the ascending slope was calculated at 7 and the descending slope 6 the overall slope would be 13 87 87 87 Section 3 5 Getting Started Slope Consideration...

Page 88: ... is available upon request If you intend to operate your pivot with an electric generator be sure to consult with your Western Dealer regarding generator specifications A conventional generator may not be adequate to power your machine You should also thoroughly familiarize yourself with the grounding and lockout tagout procedures set forth in the Safety Maintenance sections of this manual A Note ...

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Page 90: ...CP600 Pivot Operation Manual POM EN December 2018 90 WARNING DO NOT OPERATE MACHINE WITHOUT A PROPER EARTH GROUND REFER ENCE SECTION 6 3 Figure 3 8 Section 3 8 Getting Started Ground Rod Placement ...

Page 91: ...600 Pivot Operation Manual POM EN December 2018 91 Figure 3 9 WARNING DO NOT OPERATE MACHINE WITHOUT A PROPER EARTH GROUND REFER ENCE SECTION 6 3 91 91 91 Section 3 9 Getting Started Ground Rod Placement ...

Page 92: ... once more and evaluate potential hazards You can then either clear the hazards or adjust the pivot point so that the spans maneuver around them If you decide to adjust the pivot point off center ensure that the new pivot will not cross the path of any other pivots already operating in adjoining fields or other obstacles in the field Your pivot will be delivered on a flatbed truck To make unloadin...

Page 93: ...s Metric in millimeters mm Not Shown 1 Figure 3 11 3810 150 2904 114 5 16 457 18 4106 161 11 16 152 6 914 36 305 12 6 REINFORCING MESH 7 8 X 18 J BOLT 2 ABOVE SURFACE REBAR PERIMETER 813 32 813 32 93 93 93 Section 3 11 Getting Started Standard Pivot Pad Concrete ...

Page 94: ...CP600 Pivot Operation Manual POM EN December 2018 94 Not Shown Section 3 12 Getting Started 6 5 8 Pivot Pad Concrete ...

Page 95: ...CP600 Pivot Operation Manual POM EN December 2018 95 Pad requires approximately 13 2 cubic yards of concrete 95 95 95 Section 3 13 Getting Started High Profile Pivot Pad Concrete ...

Page 96: ... 12 813 32 2362 93 813 32 914 36 3683 145 3683 145 4 REBAR PERIMETER USE CHAIN WITH A PROOF LOAD OF AT LEAST 24 000 LBS 1 2 GRADE 8 CONSULT CHAIN MANUFACTURER THREAD REBAR THROUGH END LINK DETAIL A SCALE 1 25 PAD REQUIRES APPROXIMATELY 6 7 CUBIC YARDS OF CONCRETE Section 3 14 Getting Started Towable Pivot Pad Concrete ...

Page 97: ...ench set 7 16 through 1 1 2 1 Deep well socket set 3 8 drive 7 16 through 3 4 1 Deep well socket set 1 2 drive 9 16 through 1 1 Each 3 8 and 1 2 drive ratchet 2 Alignment bars 1 18 pipe wrench 2 12 Channel lock pliers 1 Large pry bar approximately 6 1 Regular flat screwdriver Note Since Western Corporation recommends all wiring be completed by a professional electrician tools involving the electri...

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Page 99: ...CP600 Pivot Operation Manual POM EN December 2018 99 Section 4 Panel Operation ...

Page 100: ...effect the machine will take twice as long to make one revolution around the field compared to a 100 timer setting 2 Voltage Meter Monitors voltage coming into the panel from main power source 3 Hour Meter Clocks amount of hours pivot is used 4 Main Disconnect Disconnects all incoming power from the machine Note Panel door will not open unless the Main Disconnect is in the OFF position 5 Operation...

Page 101: ...ine will travel in the direction that the Auto Reverse option is currently set to If Auto Off is used simply place the selector switch in the desired direction then Start the system Machine will move in the selected direction and stop when the machine reaches the barricade Note Forward is to be clockwise 11 Stop Run Start Stop or Start machine WARNING CARE SHOULD BE TAKEN WHEN USING THE SAFETY OVE...

Page 102: ...oltage NOTE Incoming voltage may vary depending on your location if you are not getting the correct voltage for your area contact a liscensed electrician for diagnosis 3 Move selector on panel door to Fwd position 4 Set the Percent Timer on the panel door to desired application rate NOTE Reference Sections for desired results Section 4 4 Panel Operation Forward Operation ...

Page 103: ...o the desired operation 6 Move Stop Run Start switch on panel door to Start to energize safety and latch circuit 7 Check the lights on the front of the control panel door The following lights should be ON RUNNING FORWARD SAFETY END TOWER Section 4 5 Panel Operation Forward Operation ...

Page 104: ...oltage NOTE Incoming voltage may vary depending on your location if you are not getting the correct voltage for your area contact a liscensed electrician for diagnosis 4 Set the Percent Timer on the panel door to desired application rate NOTE Reference Sections for desired results 3 Move selector on panel door to Rev position Section 4 6 Panel Operation Reverse Operation ...

Page 105: ...o the desired operation 6 Move Stop Run Start switch on panel door to Start to energize safety and latch circuit 7 Check the lights on the front of the control panel door The following lights should be ON RUNNING REVERSE SAFETY END TOWER Section 4 7 Panel Operation Reverse Operation ...

Page 106: ...ist you in the successful operation of this feature Auto Reverse Option 1 Turn the Rev Auto Fwd switch 1 to the Auto position 2 Turn the Stop Run Start switch 3 to the Start position When the machine is started with the Start switch item 3 it should run in the direction that it was last running If the opposite direction is desired start the system with the switch in the desired direction then move...

Page 107: ...CP600 Pivot Operation Manual POM EN December 2018 107 Section 4 9 Panel Operation Auto Reverse Auto Off Option 3 1 2 ...

Page 108: ...ion will automatically energize the Start circuit if in Auto starting the machine If in Hand the timer pulse is not applied to the Start circuit so the ma chine remains Off Auto Restart Off Place the selector switch in the position shown below to prevent the machine from automatically restarting after a power failure Auto Restart On Place the selector switch in the position shown below to allow th...

Page 109: ...s iControl Remote ready Using the Local iControlRemote switch you can enable or disable remote control of your center pivot Please refer to the iControl Remote documentation for more information regarding proper operation of that option To enable or disable remote control of your pivot simply move the selector switch between Panel disabled and iControl Remote enabled ...

Page 110: ...tactor and direction wires to energize allowing machine movement as necessary WARNING CARE SHOULD BE TAKEN WHEN USING THE SAFETY OVERRIDE FEATURE SEVERE MISALIGNMENT MAY RESULT IN STRUCTURAL DAMAGE DO NOT USE OVERRIDE UNLESS MACHINE IS IN COMPLETE VIEW The machine Safety shutdown feature may be overridden by moving the Direction switch to For ward or Reverse pressing the Safety Override button and...

Page 111: ...ch tower junction box see Figure 4 12a and Figure 4 12b Turning this switch to the OFF position will shut down the entire machine by interrupting the safety circuit This switch is not the machine disconnect and should ONLY be used in emergencies Figure 4 12a Figure 4 12b The pictures shown may not depict what your machine may have Your tower junction box may be equipped with a gray cover and also ...

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Page 113: ...CP600 Pivot Operation Manual POM EN December 2018 113 Section 5 Electrical ...

Page 114: ...sformer however is not recommended because there are only three wires from the transformer to the service entrance Most newer installations will have three power leads and a ground from the transformer to the main service entrance If only three leads are provided from the transformer a grounding lead should be installed from the transformer to the service panel to ensure a low impedance path to gr...

Page 115: ...EN December 2018 115 Note Field Wiring Use Copper or Aluminum conductors for at least 60 C Recommended screw tightening torque is 4 4 lb in 0 5 Nm SPAN CABLE SIDE PANEL SIDE Section 5 3 Electrical Standard Panel Span Cable Connections ...

Page 116: ...CP600 Pivot Operation Manual POM EN December 2018 116 Section 5 4 Electrical Panel Wiring 90239 41_R4 1 8 9 2 3 ...

Page 117: ...CP600 Pivot Operation Manual POM EN December 2018 117 Section 5 5 Electrical Panel Wiring 90239 41_R4 5 6 14 17 13 15 16 12 18 11 10 20 19 4 ...

Page 118: ...2 11 CONTACT BLOCK NC SIEMENS 3SU1400 1AA10 3CA0 10 12 860145 1 PLUG IN RELAY with BASE PUSH IN TERMINAL 115VAC 4C O SIEMENS LZS PT5D5S15 11 12 860153 1 MINICIRCUIT BREAKER 6A 1P 230 400V 6kA SIEMENS 5SY4106 6 12 12 860158 1 TIMER DELAY SAFETY SIEMENS 3RP2540 2AW30 13 12 860131 1 CONTACTOR FWD REV SIEMENS 3RA2326 8XB30 2AK6 14 12 860132 1 CONTACTOR 18A 120VAC SIEMENS 3RT2015 2AK61 15 12 860157 25 ...

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Page 120: ...CP600 Pivot Operation Manual POM EN December 2018 120 Section 5 8 Electrical Standard Panel Schematic ...

Page 121: ...CP600 Pivot Operation Manual POM EN December 2018 121 Section 5 9 Electrical Standard Panel Schematic ...

Page 122: ...CP600 Pivot Operation Manual POM EN December 2018 122 1 2 Section 5 10 Electrical CP JB Intermediate Cam 10142 01 ...

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Page 124: ...CP600 Pivot Operation Manual POM EN December 2018 124 1 2 Section 5 12 Electrical EndT ower JunctionBoxw outAutoReverseandBooster90017 01 ...

Page 125: ...CP600 Pivot Operation Manual POM EN December 2018 125 1 2 3 Section 5 13 Electrical Stall Timer Wiring 90016 01 ...

Page 126: ... Control Panel Out to Tower No 1 Collector Ring WARNING MAKE SURE WIRES CLEAR BRUSH POSTS WHEN MACHINE ROTATES WARNING DO NOT CONNECT 6 WIRE TO 9 WIRE Note See WARNING regarding proper ground brush wiring Section 5 23 Section 5 14 Electrical Collector Ring Wiring ...

Page 127: ...BRUSH THE RACEWAY BRUSH IS GROUNDED TO THE COLLECTOR RING BASE FAILURE TO PROPERLY GROUND YOUR PIVOT WILL RESULT IN SERI OUS INJURY OR POSSIBLE DEATH Note Wire color in Span Cable is subject to change without notice Reference will be made here on out to yel red wire Depending upon purchase date your Span Cable may be equipped with tan yellow red replaces tan ...

Page 128: ...CP600 Pivot Operation Manual POM EN December 2018 128 Section 5 16 Electrical Notes ...

Page 129: ...CP600 Pivot Operation Manual POM EN December 2018 129 Section 5 17 Electrical Notes ...

Page 130: ...CP600 Pivot Operation Manual POM EN December 2018 130 Section 5 18 Electrical Notes ...

Page 131: ...CP600 Pivot Operation Manual POM EN December 2018 131 Section 5 19 Electrical Notes ...

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Page 134: ...134 POM EN December 2018 www western irrigation com ...