Toro OSMAC
®
RDR Field Satellite
Electric Actuation Models
Installation Instructions
Introduction
The OSMAC RDR Satellite Controller is designed for installation on a substantial concrete foundation with imbedded conduit of various diameters to enable power, field and earth ground wiring to be routed into the cabinet for connection.
A mounting bolt positioner and basic mounting hardware components are included with each controller. Additional materials required to complete the installation must be obtained separately. A material list can be compiled by reading through the instructions completely prior to starting the installation.
CAUTION: For your protection and the safety of the product user, comply with all Caution and Warning statements within this document. All installation practices must comply with all applicable national and/or local electrical and construction codes.
Foundation Construction
1. Prepare a hole for the foundation and wiring conduit using the minimum recommended dimensions shown in
Figure 1.
Note: Refer to local electrical codes for required depth of buried wiring.
2. Trench to the foundation site as required for each wiring run.
3. Position straight and sweep elbow conduit sections in foundation hole as shown. Tape the conduit ends to seal out dirt. Backfill soil to form a 6"
(15.2cm) foundation depth. Conduit should not extend more than 2" (51mm) above the finished top surface of the foundation.
4. Prepare the sides of the foundation hole with wood forms.
5. Prepare the mounting bolt positioner with the 5/16 x 4-1/2" bolts and nuts
(provided) as shown in Figure 1. The threads should extend 2" (51mm) from the top surface of the bolt positioner.
6. Pour concrete into the formed foundation hole. Press the mounting bolt positioner into the concrete until it is flush and level with the foundation
surface and aligned with the conduit.
7. Finish the concrete with a level flat area of 16" x 16" (41cm x 41cm) for the pedestal base. To prevent pooling at the base of the pedestal, add a slight taper away from the cabinet base contact area. Allow concrete to sufficiently harden before continuing.
8. Remove the hex nuts from the mounting studs. Remove the cabinet cover and doors. Carefully position the controller onto the studs. Install a flat washer and a hex nut on each stud and tighten securely.
Figure 1 Wood Form
Plastic Cabinet Base Area
(Conduit Recommendations)
3/4" (19mm) – Power
2" (51mm) – Field
(24 Stations Each)
Mounting Bolt Positioner
3/4" (19mm) – Earth Ground
2" (51mm) Max.
6" (15.2cm)
Mounting Bolt
Positioner
2"
(51mm)
FRONT
30"
(76cm)
30"
(76cm)
Taper
See *Note
Earth Ground Installation
Important: The satellite surge protection components cannot properly function unless an efficient pathway to earth ground is provided. The ground path must be as direct as possible, without sharp bends and must not exceed 30 ohms resistance (when measured with an earth ground resistance test device). A resistance reading of 0–10 ohms is considered excellent, 11–20 ohms is acceptable and 21–30 is considered marginal. All electrical components throughout the irrigation system should be grounded in a manner which provides the same ground potential.
The following instructions depict one of several acceptable earth grounding methods. Due to variables in soil composition and terrain, the method shown may not be suitable for your installation site. Contact your local Toro distributor for assistance and availability of the required earth ground resistance test instrument. Recommended ground testers are:
AEMC Instruments, model 3710 clamp-on tester, or Biddle Megger, model 250260 (or equivalent).
Procedure
1. Drive a 5/8" (16mm) by 8' (2.5m) copper-clad steel rod into wellmoistened soil not less than 8' (2.5m) or more than 12' (3.7m) from the satellite.
The top of the ground rod should be
12" (30.5cm) below grade level.
2. Using a 5/8" (16mm) clamp or
“Cad weld” fastener, attach a length of
6 AWG (10mm 2 ) solid-core, bare copper wire near the top of the ground rod.
Avoiding wire bends of less than 8"
(2.3cm) radius, route the wire through the foundation into the controller cabinet. Secure the wire to the large copper ground lug provided on the rear plate asembly. See Figure 2.
Note: The ground lugs provided on the surge protection assemblies (if installed) are not used in this application.
Figure 2
Valve Box
12"
(30.5cm)
Ground Wire To
Additional Ground
Rod(s) (Optional)
Copper-Clad
Ground Rod
Chassis
Ground Lug
6 AWG (10mm 2 )
Ground Wire
8" (20.3cm)
Radius Minimum
8'–12' (2.4m–3.7m)
Pump 1
2
3
4
90˚
3. Ensure the soil surrounding the ground rod remains well moistened at all times. Measure the ground resistance per the instructions provided with the ground test instrument. A reading of 0 ohms is optimum, up to 10 ohms is good and
11–30 ohms is acceptable in most cases. If the resistance exceeds the acceptable limit, an additional ground rod can be installed at a distance equal to twice the buried depth of the first rod (i.e., 16' [4.9m]). Connect the ground rods using
6 AWG (10mm 2 ) bare copper wire and test again. If the ground resistance remains high, contact your local Toro distributor for further assistance and recommendations.
Connecting Power and Equipment Ground Wires
CAUTION: When installing multiple controllers, polarity of the Line and Neutral connections must be properly maintained throughout the irrigation system. Reversed polarity may cause damaging potentials to exist at one or more controller locations.
WARNING:
AC Power wiring must be installed and connected by qualified personnel only.
All electrical components and installation procedures must comply with all applicable local and national codes. Some codes may require a means of disconnection from AC power source, installed in the fixed wiring, having a contact separation of at least 0.120" (3mm) in the line and neutral poles.
Ensure the AC power source is OFF prior to connecting to the controller.
1. Place the controller’s main power switch in the OFF position. See Figure 3.
2. Position the input voltage select switch to the 115V or 230V position as required.
3. Remove the power supply cover located in back of the RDR unit.
4. Connect the provided 3/4" (19mm) electrical conduit in the satellite to the 3/4" (19mm) electrical conduit installed in the foundation.
5. Route three insulated solid copper wires from the power source, through the conduit, and into the controller power supply.
2
Figure 3 Figure 4
Line
Ground
Neutral 3.2A Fuse
4.0A Circuit
Breaker
Main Power Switch ON
OFF
WARNING
HIGH
VOLTAGE
115V
Input Voltage
Select Switch
Table 1 – Power Wire Connnection
AC Service Type
115 V a.c. (Domestic)
230 V a.c. (3-Phase)
Line
Hot (Black)
Hot (Black)
Equipment Ground
Green
Green/Yellow
Neutral
Neutral (White)
Hot (Blue or Red)
6. Reference Table 1 for the appropriate type of power connection. Secure the wires to the terminal block as indicated in
Figure 4.
7. Reinstall the power supply cover.
8. Apply power to the controller.
Connecting Control Valve Wiring
1. Attach a control wire to one lead of each valve solenoid. Attach a common wire to the remaining lead of all valve solenoids.
Waterproof all field wire connections using an approved waterproof splicing method.
2. Label control wires and common wire(s) for identification during installation. Route the wires through the 2" (51mm) conduit into the controller cabinet.
3. Secure valve control wires to station terminals in desired operating sequence. Secure common wire(s) to COM terminals of pump/common surge module. (Three common terminals are provided.) See Figure 5.
Note: The 24-station model is shown in the illustration. Models with
32–48 stations have additional surge modules located on the rear chassis plate.
All station outputs are labeled with the appropriate station number.
CAUTION: If connecting more than one valve per station, do not exceed 0.75A (18 VA) maximum.
Figure 5
Station
Terminal s
STA 9
STA 10
STA 11
STA 12
STA 13
STA 14
STA 15
STA 16
STA 1
STA 2
STA 3
STA 4
STA 5
STA 6
STA 7
STA 8
STA 17
STA 18
STA 19
STA 20
STA 21
STA 22
STA 23
STA 24
Pump
Terminal
3
4
2
1
Common
Terminals
3
Connecting A Master Valve or Pump Relay
1. Secure a wire pair from the master valve or pump relay and route it into the satellite pedestal with the field wires. See Figure 6 for pump relay configurations.
2. Connect one wire to the pump terminal of the pump/common surge module.
3. Connect the remaining wire to one of the common terminals.
CAUTION: Do not connect the pump starter directly to the controller’s pump start circuit.
Damage to the controller will result. Use a
24 V a.c., 0.75 Amp (max) pump start relay.
Figure 6
Pump
Terminal
Common
Terminal
PUMP
Pump Common
Surge Module
Pump
Com
Relay
24 V a.c.
Starter
Power
Source
Pump Power
Source
Mag.
Pump
Starter
Pump
R
To Other Controllers
Pump
Com
Pump
Com
Relay
24 V a.c.
Starter
Power
Source
Pump Power
Source
Mag.
Pump
Starter
Pump
Pressure
Switch
Pump
Com
Relay
24 V a.c.
Starter
Power
Source
Pump Power
Source
Mag.
Pump
Starter
Pump
Selecting Operating Mode
The valve station and pump/common surge protection modules incorporate slide switches which enable three operating modes to be selected for each valve station. Set switches to the type of operation mode required:
• AUTO position enables the station circuit to function automatically per controller operation.
• OFF position disables the station until the switch is moved to
AUTO or ON.
• ON position manually activates the station until the switch is moved to AUTO or OFF.
Figure 7
R
ON OFF AUTO
ON OFF AUTO
ON OFF AUTO
CAUTION: When operating stations manually, do not exceed 3.0A maximum current draw. Controller component damage can result.
Note: The pump/common switch on the surge module controls the pump circuit only – the valve common circuit is not affected by switch position.
Selecting the Narrow-band Decoder Radio Frequency
Note: Wide-band radio models only – Install the wide band frequency module into the RDR unit at this time. Refer to
Installation Instruction (form number 371-0002) provided with the frequency module for proper installation procedure.
The narrow-band satellite frequency decoder module provides four preprogrammed frequencies, one of which is selected for use by the placement of a movable jumper located on the module board as shown in Figure 8.
The pre-programmed frequencies are as follows:
Channel 1=462.2125 Mhz
Channel 2=462.4375 Mhz
Channel 3=467.2125 Mhz
Channel 4=467.4375 Mhz
Figure 8
Note: The decoder module utilizes a programmable frequency synthesizer which enables each of the preprogrammed frequencies to be changed as needed for the irrigation site conditions. Contact your local Toro distributor for additional information regarding frequency reprogramming.
#4
#3
#2
#1
Important: The base station transmitter, hand-held radio and frequency decoder module must be set to the same frequency to enable communication.
4
Assigning the Satellite Address Number
Figure 9
Each satellite requires a 3-digit address number to enable communication with the central controller and/or a hand-held radio. The address numbers range from 1 (001) through 255 and are selected using an array of eight DIP switches located on the frequency decoder module assembly. See Figure 9. In the down position, the switch is Off (open) and represents a value of 0
(zero). In the up position, the switch is On (closed) and represents one of the following binary numbers:
1, 2, 4, 8,16, 32, 64 and 128.
The wide-band DIP switch array is configured as follows:
Sw 1 = 128 Sw 2 = 64 Sw 3 = 32 Sw 4 = 16
1 2 3 4 5 6 7 8
O
N
1 2 3 4 5 6 7 8
Sw 5 = 8 Sw 6 = 4 Sw 7 = 2 Sw 8 = 1
The narrow-band DIP switch array is configured as follows:
Sw 1 = 1 Sw 2 = 2 Sw 3 = 4 Sw 4 = 8
OFF
Wide-band DIP switch location
Sw 5 = 16 Sw 6 = 32 Sw 7 = 64 Sw 8 = 128
To set the satellite address number, place the switch or combination of switches to the On position which provides the numerical equivalent of the desired address number.
Example for wide-band radio: To set satellite address number 50 (050), start with all eight DIP switches in the Off
(open) position, then close switch numbers 3, 4 and 7; i.e., 32 (Sw 3) + 16 (Sw 4) + 2 (Sw 7) = 50. See switch address code matrix in Table 2.
Example for narrow-band radio: To set satellite address number 50 (050), start with all eight DIP switches in the Off
(open) position, then close switch numbers 2, 5 and 6; i.e., 2 (Sw 2) + 16 (Sw 5) + 32 (Sw 6) = 50. See switch address code matrix in Table 2.
Note: The narrow band satellite utilizes a built-in antenna located on the frequency module assembly. If site conditions are such that an alternate antenna is required, the optional antenna adapter kit (P/N 102-1204) is required.
Testing Satellite Operation (narrow-band models only)
• Performing a Control Circuit Self Test
A self-test feature is provided to check the functionality of various key satellite control circuits. Before performing the test, ensure the Pump/Common module and the Valve Station module switches are set to the
AUTO position.
Figure 10
The test is initiated by positioning the TEST / RESET switch, located on the frequency decoder module, to the TEST position as shown in Figure 10. Testing will begin immediately. The test will repeat continuously until the TEST / RESET switch is positioned to the center (normal operation) position.
4 Amp
"Slow Blow" Fuse
Note: The
RESET position resets the frequency decoder microprocessor to factory defaults. To take affect, the satellite must be powered up with the switch in the
RESET position. The switch should be placed in the
NORMAL position after 15 seconds of operation.
• Performing a Station Output Test
Ensure the Pump/Common module switch is in the
ON position. Position each
Valve Station module switch to the
ON position one at a time and confirm sprinkler operation.
Figure 11
“Surge Pills”
P/N 360-0471
Service Components
Surge Devices – The surge protection modules utilize replaceable, clip-mounted surge protection devices for each Valve Station and
Pump/Common terminal. The surge protection devices installed are quick reaction, gas ionization type, commonly called “surge pills,” which momentarily shunt high voltage directly to earth ground. Depending on the frequency and severity of lighting strikes incurred, the surge pills can generally withstand several high voltage surges before malfunction occurs. To ensure proper surge pill condition, a periodic test schedule should be established and maintained.
Contact an authorized Toro distributor for service assistance.
5
R
R
3 Amp “Slow Blow”
Fuse P/N 363-1222
Fuse – A 3 Amp “Slow Blow” fuse is utilized on the Valve Station modules and a 4 Amp “Slow Blow” fuse is utilized on the
Station Output modules.
CAUTION: For continued protection against risk of fire, replace only with the same type and rating of fuse.
Remote Relay Function And Connection
The OSMAC RDR frequency decoder module is equipped with a single-pole, double throw relay that is rated at 5 amps. The relay is intended for use in irrigation installations that have two different irrigation systems. Upon command transmitted from the base station or a hand-held radio, the relay can be energized. This will stop all
OSMAC RDR functions and turn power on to the alternate irrigation system. Another command can be sent to the RDR to turn off the relay, de-energizing the alternate system and returning control to the
OSMAC RDR. Additionally, a command is provided to disable this feature so it cannot be accidentally invoked and a different command to enable the feature.See the Command Code list for specifics.
See Figure 12 for terminal locations.
Figure 12
COM
1
Narrow Band Freq. Decoder Module
Wide Band Freq. Decoder Module
24 V a.c.
2
Normally
Closed
3 4 5
Optional Relay Socket
(Wide Band Only)
6 7 8
Common
Pin
Normally
Open
Satellite Operations Using a Hand-Held Radio
Satellite operations can be initiated in the field using a hand-held radio keypad. All operation commands must begin with the following keypad sequence: *9 followed by the 3-digit satellite address number. The command code is then entered, followed by additional digits which represent selected stations and/or run time values. All station numbers from 1–9 must be entered with a preceding 0; i.e., station 1 is entered as 01. Refer to Table 2 for command codes and operation descriptions
Example: Confirm communication to the satellite by issuing a manual station start command as follows: Press *9, the
3-digit satellite address code, command code 7521 and 01 (station 1). Visually check for sprinkler operation. To step forward through the stations, press *1; to step back through the stations, press *2. To terminate the test, use command code 7520.
Table 2 – Hand-held Radio Command Codes
Command Code
7510
7511
7512
7513
Operation Description
Turns off individual stations; e.g., 7510 01 02 40 turns off stations 1, 2 and 40.
Turns on individual stations; e.g., 7511 01 02 40 turns on stations 1, 2 and 40.
Syringes individual stations for a predetermined number of 30-second intervals (already defined in the satellite); e.g., 7512 01 02 turns on stations 1 and 2 for 30-second intervals.
Disables individual stations; e.g., 7513 01 03 disables stations 1 and 3. After this command, on and off commands will be ignored for stations 1 and 3 until the stations are re-enabled.
(See 7514.)
7514
7515
7516
7517
Enables individual stations; e.g., 7514 01 03 enable stations 1 and 3.
Sequentially syringes a specified station number range; e.g., 7515 10 20 will syringe stations
10 through 20 sequentially.
Sequentially syringes individual stations; e.g., 7516 10 11 will syringe stations 10 and 11.
Note: Multiple syringe groups can also be run (base station command only - not applicable to hand-held radio). Enter two dashes between stations to designate separate syringe groups; e.g.,
7516 10 11 - - 22 24 26 28 will run two syringes at the same time. First on stations 10 and 11, followed by stations 22, 24, 26 and 28.
Turns on individuals stations for a specified number of hours, minutes and seconds; e.g.,
7517 01 30 00 23 24 25 turns stations 23, 24 and 25 on for 1 hour, 30 minutes and no seconds.
7518
7520
7521
7524
Turns on individual stations for a specified number of minutes; e.g., 7518 10 23 24 25 turns on stations 23, 24 and 25 for 10 minutes.
Turns off a sequential station run operation (initiated by command code 7521).
Turns on a sequential station run operation; e.g., 7521 01 turns on station 1. To step forward through the stations, press *1; to step back through the stations, press *2.
Turns on individual stations as switches; i.e., does not simultaneously energize the pump.
Note: Will not turn off the pump if already running. E.g., 7524 25 35 45 turns on stations 25, 35 and 45 without energizing the pump.
6
Table 2 – Hand-held Radio Command Codes (continued)
Command Code
7525
7526
7540
7543
7544
7546
7800
7801
7810
7811
8000
8001
8003 00
8003 01
8004
8006 01
8006 02
8006 03
8008
8009
8011
Operation Description
Turns on individual stations as switches for a time given in minutes; i.e., does not simultaneously energize the pump in this command string, the run time is entered first, followed by the station numbers; e.g., 7525 25 05 42 turns on stations 5 and 45 for 25 minutes without energizing the pump.
Turns on individual stations as switches for the time given in hours, minutes and seconds.
In this command string, the run time is entered first, followed by the station numbers; e.g., 7526 02
30 45 25 26 27 turns on stations 25, 26 and 27 for 2 hours, 30 minutes and 45 seconds.
Turns off all stations (this satellite only).
Disables all stations in all satellites (rain shutdown). Note: Satellite address code 256 is used with 7543 and 7544 command codes. The stations will not respond to any further commands until enabled.
Enables operation of all stations in all satellites. See Note above.
Sequentially syringes all stations for a set length of time; e.g., 7546 turns on all stations for the predetermined number of 30 second intervals as defined in the syringe time.
Disable the remote relay on the frequency decoder module.
Enable the remote relay on the frequency decoder module.
Turns off the remote relay on the decoder module. Resumes function to the satellite unit.
Turns on the remote relay on the decoder module. Disables function to the satellite unit.
Disables pump start.
Enables pump start to be assigned to a station; e.g., 8001 48 assigns pump start to station 48.
Disables operation and turns off all stations in the satellite with sequential shutdown.
Enables operation of all stations in the satellite.
Changes the password; e.g., 8004 7531 6108 will change the factory default password (7531) to
6108.
Sets the syringe time in 30-second intervals; e.g., 8006 01 0100 (without a password) or 8006 pppp 01 0100 (with a password) sets the syringe time to 100 intervals (50 minutes). The number of intervals must be given as four digits with leading zeros but can be no greater than 0255.
Sets the time-out limit in 30-minute intervals. This must be specified using four digits with leading zeros and no greater value than 0255; e.g., 8006 02 0060 (without a password) or 8006 pppp 02 0060 (with a password) sets the time-out limit to 30 hours.
Enables/disables the password. Use 8007 03 01 to enable password protection or 8007 03 00 to cancel password protection.
Configures stations as switches. Stations can be specified individually and in combination with a range of stations; e.g., 8008 01 12 50 – 60 configures stations 1, 12 and 50 through 60 as switches. Note: Only a single dash is used when entering a range of stations.
Configures stations for irrigation. Stations can be specified individually and in combination with a range of stations; e.g., 8009 01 20 45 – 48 configures stations 1, 20 and 45 through 48 for irrigation.
Resets EPROM to factory defaults.
Specifications
Line Voltage: 115/230 V a.c. 50/60 Hz (switchable),
130 VA (100W)
Current Draw (no load): 0.07A @ 115V, 60 Hz,
0.09A @ 230V, 50 Hz
Current Draw (maximum load): 0.76A @ 115V, 60 Hz,
0.41A @ 230V, 50 Hz
Secondary Voltage Output: 24 V a.c.,50/60 H,
3.0A (72 VA)
Maximum Load Per Station Output:
0.75A (18 VA)
Maximum Load Per Pump/Master Valve Output:
0.75A (18 VA)
Maximum Total Load: 3.0A (72 VA)
Hardware Features
Plastic: 44 1/2" x 16" x 15" (113.0 cm x 40.6 cm x 38.1 cm)
Top Locking Cover
Fuses and Circuit Breakers
Power Supply:
1.5A On/Off Switch/Circuit Breaker – Main Power Input
3.2A Fuse (Slow-Blow) – Field Output
4.0A Fuse (Slow Blow) – Station Output Module
4.0A Circuit Breaker – Control Functions
Pump/Common & Communication Surge Protection Module:
0.5A Fuse
7
Table 3 – Satellite Address DIP Switch Matrix
• =On =Off WB=Wide Band NB=Narrow Band
WB
045
046
047
048
049
050
051
039
040
041
042
043
044
033
034
035
036
037
038
025
026
027
028
029
030
031
032
019
020
021
022
023
024
011
012
013
014
015
016
017
018
NB
001
002
003
004
005
006
007
008
009
010
8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8
WB
096
097
098
099
100
101
102
090
091
092
093
094
095
082
083
084
085
086
087
088
089
076
077
078
079
080
081
068
069
070
071
072
073
074
075
062
063
064
065
066
067
NB
052
053
054
055
056
057
058
059
060
061
8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8
WB
147
148
149
150
151
152
153
141
142
143
144
145
146
133
134
135
136
137
138
139
140
127
128
129
130
131
132
121
122
123
124
125
126
113
114
115
116
117
118
119
120
NB
103
104
105
106
107
108
109
110
111
112
8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8
WB
NB
195
196
197
198
199
200
201
202
203
204
187
188
189
190
191
192
193
194
181
182
183
184
185
186
175
176
177
178
179
180
167
168
169
170
171
172
173
174
161
162
163
164
165
166
154
155
156
157
158
159
160
8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8
WB
NB
244
245
246
247
248
249
250
251
252
253
254
255
238
239
240
241
242
243
232
233
234
235
236
237
224
225
226
227
228
229
230
231
218
219
220
221
222
223
205
206
207
208
209
210
211
212
213
214
215
216
217
8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8
Electromagnetic Compatibility
Domestic: This equipment has been tested and found to comply with the limits for a FCC Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. The equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to the radio communications. Operation in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.
International: This is a CISPR 22 Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be required to take adequate measures.
© 2002 The Toro Company, Irrigation Division • An ISO-9001-Certified Facility Form Number 373-0203 Rev. B
