OPERATION MANUAL
for
BAUER - LINESTAR 5000
Version:V / 2007
INTRODUCTION
Thank you for buying BAUER LINESTAR 5000!
The present manual is a very important document that describes how to operate and service BAUER
LINESTAR 5000.
This manual describes the system as detailed as possible. If you need still more information, please
contact your dealer or turn directly to BAUER in Voitsberg.
Please note that the content of this manual neither constitutes part of nor alters in any way any previous or
existing agreement, promise or legal relationship. BAUER’s commitment is based solely on the respective
purchase contract which also contains the complete and only valid warranty agreement. Said contractual
warranty is neither extended nor limited by the content of this manual.
All information contained in the present manual is based on the latest product details available at the time
of printing.
BAUER reserves the right to change without notice without assuming any liability!
BAUER - LINESTAR 5000 is designed for highest performance safety and reliability provided it is operated
in accordance with the present operating instructions.
Therefore you should study this manual thoroughly before starting your BAUER - LINESTAR 5000!
Strictly observe all instructions pertaining to system handling, operation and service!
On this condition, BAUER - LINESTAR 5000 will operate to your satisfaction for many years!
Non-observance of this manual may cause personal injury or damage the equipment!
This manual is to be considered an integral part of BAUER - LINESTAR 5000. Suppliers of both new and
used systems are advised to put down in writing that they delivered the manual together with the system.
Please make this manual available to your staff. State the pump type and serial number of your
BAUER - LINESTAR 5000 in all inquiries, correspondence, warranty problems, or parts orders.
We wish you a lot of success with your BAUER - LINESTAR 5000!
Operation Manual for BAUER LINESTAR 5000
II
Owner of the machine
This machine with the serial number
Belongs to
Name
Address
residence
Telephone number
Tutor:
Bauer dealer
Service – technician
Telephone number
Operation Manual for BAUER LINESTAR 5000
III
Handing over record
A duly test run has been done in the presence of the customer or a nominated agent of
the customer. The customer confirms by signing that the machine has been test run
before taken over. A copy pf the handing over record needs to be sent back to the
company BAUER Ges.m.b.H.
Comments:
For the customer
______________________________
Operation Manual for BAUER LINESTAR 5000
For the company BAUER GMBH
______________________________
IV
Product details
Date of delivery
.......................................................................................
Date of initial operation .......................................................................................
Type
BAUER LINESTAR 5000
Serial number
……………………………………………………………………
Central tower
2 wheels ………………………….4 wheels………………….....………...
Configuration of span
……………………………………………………………….……
Spans
fixed.............................................towable…………………………..........
Booster pump
yes………………………………....no……………………………......…......
End gun
yes…………………………………no……………………………………….
Equipment
...............................................................................................
Linear control
cable…
Water supply
ditch………………..........……..hose………………………................
Feeding hose
diam.……….............................length……………………………......
Generator unit
……………….....furrow……………………................
………………………………………………………………………....………
Comments
..............................................................................................
..............................................................................................
Producer of the machine:
Röhren- und Pumpenwerk BAUER Ges.m.b.H.
Kowaldstrasse 2
A – 8570 Voitsberg
Tel.: +43 3142 200 – 0
Fax: +43 3142 200–320 / -340
e-mail: sales@bauer-at.com
www.bauer-at.com
Dealer:
Name:
………………………………………………………………….
Address:
………………………………………………………………….
………………………………………………………………….
Tel. / Fax:
………………………………………………………………….
Operation Manual for BAUER LINESTAR 5000
V
INDEX
1
GENERAL INSTRUCTIONS ............................................................................................................................................. 2
2
WARNING SYMBOLS ...................................................................................................................................................... 3
3
GENERAL......................................................................................................................................................................... 4
4
GENERAL INSTRUCTIONS FOR SAFETY AND ACCIDENT PREVENTION ................................................................. 5
5
SAFETY PRECAUTIONS FOR LINESTAR 5000 ............................................................................................................. 5
5.1
5.2
6
ELECTRICAL SYSTEM ............................................................................................................................ 5
MECHANICAL SYSTEM .......................................................................................................................... 6
TECHNICAL DESCRIPTION ............................................................................................................................................ 7
6.1
COMPONENTS OF THE LINESTAR 5000 .............................................................................................. 7
6.2
CENTER FEED – END FEED .................................................................................................................. 8
6.2.1
Center feed ........................................................................................................................................ 8
6.2.2
End feed ............................................................................................................................................ 8
7
USE OF LINESTAR .......................................................................................................................................................... 9
7.1
LIMITS ...................................................................................................................................................... 9
7.1.1
Inclination .......................................................................................................................................... 9
7.1.2
Permissibe bending angles ............................................................................................................... 9
7.2
TRACK DETERMINATION AND MAINTENANCE................................................................................. 10
7.2.1
Travel direction ................................................................................................................................ 10
8
LINESTAR CENTRAL TOWER ...................................................................................................................................... 11
8.1
8.2
9
FOUR-WHEEL CENTRAL TOWER ....................................................................................................... 11
TWO-WHEEL CENTRAL TOWER ......................................................................................................... 12
CONTROL CENTER....................................................................................................................................................... 13
9.1
10
Standard built-in components ................................................................................................................. 14
LINEAR CONTROL SYSTEM .................................................................................................................................... 24
10.1
10.2
10.3
10.4
FURROW GUIDANCE ........................................................................................................................... 24
CABLE GUIDANCE INSTALLATION AND ADJUSTMENT ................................................................... 25
SETTING LINEAR CONTROL ............................................................................................................... 27
SETTING STOP SWITCH ...................................................................................................................... 28
11
DIESEL GENERATOR UNIT ...................................................................................................................................... 30
12
ALIGNMENT OF THE LINESTAR .............................................................................................................................. 30
12.1
13
13.1
14
MICROSWITCH ADJUSTMENT ............................................................................................................ 32
ELECTRICAL SYSTEM .............................................................................................................................................. 33
14.1
14.2
14.3
15
ALIGNING THE CENTRAL TOWER PARALLEL TO THE LINEAR GUIDANCE (FURROW, CABLE) 30
ALIGNMENT CONTROL ............................................................................................................................................ 32
CABLES AND MARKINGS ..................................................................................................................... 33
INSTALLATION, CONNECTION OF CONTROL CENTER ................................................................... 34
ALIGNMENT CONTROL CONNECTION ............................................................................................... 34
FIRST START-UP ....................................................................................................................................................... 35
15.1 CHECKING OF CENTRAL UNIT ........................................................................................................... 35
15.2 CHECKING OF TRUSS, END TOWER AND OVERHANG ................................................................... 35
15.3 GEARBOXES AND DRIVE MOTORS.................................................................................................... 36
15.3.1 Gearboxes ....................................................................................................................................... 36
15.3.2 Drive motor ...................................................................................................................................... 36
15.4 CONTROL CENTER .............................................................................................................................. 37
15.4.1 Checking voltage and wiring ........................................................................................................... 37
15.4.2 Checking tower travel direction ....................................................................................................... 37
15.5 ALIGNMENT OF THE TOWERS............................................................................................................ 38
15.5.1 Control Center Linear Pro ............................................................................................................... 38
15.6 ALIGNMENT CONTROL ADJUSTMENT ............................................................................................... 38
Operation Manual for BAUER LINESTAR 5000
VI
15.7
CHECKING ALIGNMENT ....................................................................................................................... 40
16
TERMINOLOGY ..........................................................................................................................................................40
17
START-UP...................................................................................................................................................................41
17.1 Start Linestar in operating mode “Linear” ............................................................................................... 41
17.1.1 Start Linestar with hose feed ........................................................................................................... 41
17.1.2 Start Linestar with ditch feed ........................................................................................................... 41
17.2 Starting after intermediate stop ............................................................................................................... 42
17.3 Shut-down procedure.............................................................................................................................. 43
17.3.1 System shut off during irrigation ...................................................................................................... 43
17.3.2 Automatic system shut off at field end ............................................................................................. 43
17.4 Starting LINESTAR to run in opposite direction after an automatic shut-down ...................................... 43
17.5 Starting the LINESTAR in operating mode „Wheel swivelling” ............................................................... 44
17.6 Starting the LINESTAR in operating mode „Pivoting“ ............................................................................. 45
17.7 Shut down procedure .............................................................................................................................. 46
17.7.1 LINESTAR shut down during irrigation ............................................................................................ 46
17.7.2 Automatic shut-off of LINESTAR ..................................................................................................... 46
17.7.3 STARTING INTO OPPOSITE DIRECTION AFTER AUTOMATIC SHUT-DOWN OF
LINESTAR ...................................................................................................................................................... 46
18
MAINTENANCE INSTRUCTIONS...............................................................................................................................46
18.1 SERVICE INTERVALS ........................................................................................................................... 46
18.2 SERVICE PLAN ...................................................................................................................................... 47
18.3 POST-SEASON MAINTENANCE ........................................................................................................... 49
18.4 PRE-SEASON MAINTENANCE ............................................................................................................. 49
18.4.1 Preload forces and tightening torques of bolts ................................................................................ 50
19
TROUBLESHOOTING ................................................................................................................................................51
19.1
20
RESTART AFTER DOGLEGGING ......................................................................................................... 52
TECHNICAL DATA .....................................................................................................................................................53
20.1
20.2
20.3
21
DIMENSIONS OF BAUER LINESTAR 5000 – 2 WHEEL ..................................................................... 53
DIMENSIONS OF BAUER LINESTAR 5000 – 4 WHEEL ONE SIDED ................................................ 53
DIMENSIONS OF BAUER LINESTAR 5000 – 4 ‚WHEEL DOUBLE SIDED ......................................... 54
OPTIONS ....................................................................................................................................................................54
21.1
21.2
21.3
21.4
21.5
21.6
21.7
21.8
21.9
21.10
22
LOW PRESSURE SHUT-OFF ................................................................................................................ 54
ELECTRIC SHUT-OFF VALVE (CENTRAL TOWER) ........................................................................... 54
END GUN................................................................................................................................................ 54
BOOSTER PUMP FOR END GUN ......................................................................................................... 55
AUTOMATIC INTERVAL CONTROL ..................................................................................................... 55
AUTOMATIC „ON/OFF” AND INTERVAL CONTROL............................................................................ 55
TOWER ALIGNMENT SWITCH ............................................................................................................. 55
TAIL LIGHT ............................................................................................................................................. 55
END STOP .............................................................................................................................................. 55
STOP RAMP ........................................................................................................................................... 56
TOWING OF LINESTAR 2 WHEEL ............................................................................................................................56
22.1 TOWING THE LINESTAR FROM CENTRAL TOWER .......................................................................... 56
22.1.1 Swivelling central tower wheels ....................................................................................................... 56
22.1.2 Swivelling tower wheels ................................................................................................................... 56
22.1.3 Mounting the tow cables on 2-wheel central tower ......................................................................... 57
22.2 TOWING THE LINESTAR AT THE END TOWER ................................................................................ 58
22.2.1 Swivelling central tower wheels (proceed according to item 17.5) ............................................ 58
22.2.2 Swivelling tower wheels ................................................................................................................... 58
22.2.3 Bracing the end tower ...................................................................................................................... 59
22.3 TOWING THE LINESTAR AT A FREESTANDING SPAN ................................................................... 60
22.3.1 Swivelling central tower wheels (according to item 17.5) ................................................................ 60
22.3.2 Swivelling tower wheels ................................................................................................................... 60
22.3.3 Bracing the end tower and the central tower ................................................................................... 61
23
ELECTRICAL WIRING DIAGRAMS ...........................................................................................................................62
23.1
Linear control center Pro Modul .............................................................................................................. 63
23.1.1 Linear control center with Pro Modul – Infeed .......................................................................... 63
Operation Manual for BAUER LINESTAR 5000
VII
23.1.2
23.1.3
23.1.4
23.1.5
Linear control center with Pro Modul – Control....................................................................... 64
Linear control center with Pro Modul – Wiring diagram .......................................................... 65
Linear control center with Pro Modul – Wiring diagram .......................................................... 66
LINEAR Control panel with Pro Modul – Wiring diagram ....................................................... 67
23.2 LINESTAR control panel Linear control ................................................................................................. 68
23.2.1 Wiring diagram linear control – furrow control................................................................................. 68
23.2.2 Wiring diagram linear control – cable control .................................................................................. 69
23.3 LINESTAR Alignment control ................................................................................................................. 70
23.3.1 Standard alignment control ............................................................................................................. 70
23.3.2 Alignment control with tower alignment switch ................................................................................ 71
23.3.3 End control standard ....................................................................................................................... 72
23.3.4 End control with tower alignment switch ......................................................................................... 73
23.4 Booster pump for end guns .................................................................................................................... 74
24
SERVICE – EVIDENCE .............................................................................................................................................. 75
25
CONFORMITY CERTIFICATE ................................................................................................................................... 79
Operation Manual for BAUER LINESTAR 5000
VIII
1
GENERAL INSTRUCTIONS
CE SYMBOL
The CE symbol that has to be affixed on the machine by the manufacturer outwardly
demonstrates compliance of the machine with the directives for machines and other relevant
EU directives.
EU conformity certificate (see Annex)
WARNING !
This “Warning” symbol refers to important safety instructions in this manual.
Whenever you see this symbol be aware of possible injury hazards. Read the note
following the symbol very carefully and inform the other operators accordingly.
CAUTION !
Non-observance of this instruction may damage or destroy the machine or
individual components.
NOTE!
It is very important to observe this note or instruction carefully!
Qualified operators
These are persons who on behalf of their training, experience and instruction as well as their knowledge of relevant
standards, rules, precautions to be taken for accident prevention, and prevailing operating conditions, have been
authorised by the person in charge of plant safety to perform the respective tasks required, and in doing so are
able to recognise and avoid potential hazards. Among other things, knowledge of first-aid procedures is also
required.
Product liability
According to the product liability law every farmer is an entrepreneur!
According to §9 PHG (Product Liability Law), liability for damage to corporeal things caused by defective products
is expressly excluded. This exclusion of liability also applies to parts not manufactured by BAUER itself but
purchased from external suppliers.
Duty to furnish information
Even if he passes on the machine to a new owner later-on, the customer is obliged to hand on the operating
manual to the new owner, too. The receiver of the machine must be instructed with reference to the mentioned
regulations.
Intended use
 BAUER - LINESTAR 5000 has been constructed exclusively for use in normal irrigation (intended use).
 Any employment beyond this normal use is considered non-conforming. The manufacturer is not liable for
damage resulting from such non-conforming use, the sole liability for damage from non-conforming use is with
the user.
 Intended use also includes compliance with manufacturer’s operating, maintenance and service instructions.
 BAUER - LINESTAR 5000 may be used and operated only by persons who are familiar with the system and
aware of the hazards involved.
 Al l relevant rules for accident prevention as well as any other generally accepted specifications and regulations
relating to safety, work medicine and traffic law must be strictly observed.
 Unauthorised modifications on the machine release the manufacturer from liability for damage resulting
therefrom.
Operation Manual for BAUER LINESTAR 5000
2
2
WARNING SYMBOLS
Danger points on the pivot system are specifically marked by safety stickers. These stickers must be affixed at the
mentioned points clearly visible and serve for protection of persons working on or near the system.
1.
WARNING !
Study and observe the manual and all safety instruction carefully before you put the system
into operation.
2.
WARNING !
Before maintenance and repair work, always stop the system, disconnect all power, and read
the operating manual.
3.
WARNING !
1.
2.
3.
4.
This system is powered by 400 Volts!
Danger of electrical shock / injury hazard !
Do not attempt to check any components while the system is live!
Open the inner pivot panel door only when main switch is OFF.
WARNING !
1. The working range of the pivot must always be at a safe distance from electrical power
lines.
2. Pull towable systems only at a safe distance from electrical power lines.
Make sure that the water jet from spray nozzles and end gun does not hit electrical lines.
The water jet of the nozzles and of the end gun must not touch electrical wires!
Operation Manual for BAUER LINESTAR 5000
3
5.
WARNING !
The system can start automatically. Always keep a safe distance from the towers.
6.
WARNING !
1. Do not remove shaft guards.
2. When repair work is performed on the system, make sure that system cannot start
running automatically. Disconnect the complete system from power.
3
GENERAL
BAUER LINESTAR 5000 is an irrigation machine consisting of a 2 - or 4 - wheel central tower and a quantity of
spans.
The four-wheel models are non-towable, the two-wheel models are both non-towable and towable.
The system is supplied with water by the means of hydrants and flexible hoses. The two- and four-wheel central
tower is equipped with a diesel power generator providing the required power for the machine drive. The control
panel is also mounted onto the central tower.
The central tower and the truss elements (towers, spans) are electrically driven.
The joints (tower couplings) mounted in between the spans allow horizontal bending thus ensuring a straight run of
the system.
By varying spray nozzles and system speeds it is possible to make the water application rate match all
requirements of crop and soil.
The travel direction of the system is determined by a furrow drawn in the ground (furrow guidance) or by a
stretched cable (cable guidance).
Operation Manual for BAUER LINESTAR 5000
4
4
GENERAL INSTRUCTIONS FOR SAFETY AND ACCIDENT
PREVENTION
Check the operational safety of the machine before every star.
1. In addition to the instructions in this manual, be sure to observe all specifications generally valid for safety and
accident prevention!
2. The warning signs and notes affixed to the machine contain information essential to safe operation. Observing
them serves your own personal safety!
3. Do not start the machine unless all guards and safety devices are mounted completely and in proper working
position!
4. Acquaint yourself with all system components and controls as well as their respective functions, before you start
to work. It is too late for this when the system is already running!
5. Check the vicinity of the system before start-up (children!). Make sure that sight is unobstructed!
6. For towing, couple the device according to the instructions and fix it only at the prescribed devices!
Electrical system check-up
1. Before the first start-up, check the electrical system and ensure that the installation complies with the safety
requirements.
2. Check the electrical system visually before every start-up.
3. All work beyond normal maintenance of the system is to be performed by a qualified service person only!
4. Never repair or service any part of the before all power has been disconnected!
Maintenance
- As a rule, maintenance and cleaning work as well as repairs of malfunctions may be done only with the drive
and the motor turned off!
- Check proper seat of nuts and screws regularly, and tighten them, if needed!
- Dispose of oil, grease, and filters in accordance with regulations.
- Always disconnect system from power before starting any work on the electrical system!
- Before electrical welding on the machine or on built-on components, cut power supply or disconnect generator!
- Spare parts must meet at least the technical requirements defined by the manufacturer! This is guaranteed by
the use of original spare parts!
5
SAFETY PRECAUTIONS FOR LINESTAR 5000
In addition to the GENERAL INSTRUCTIONS FOR SAFETY AND ACCIDENT PREVENTION, the following safety
principles for operating the BAUER LINESTAR 5000. must be strictly observed.
5.1
ELECTRICAL SYSTEM
WARNING !
System is powered by 400V, so be sure to practice utmost caution when handling the electrical system and
the electric drive!
Operation Manual for BAUER LINESTAR 5000
5
1. All metal parts of the unit must be interconnected, all tower couplings must be bridged with a cable.
2. In addition the yellow-green earth conductor, which goes with the power supply, must be connected to the
protective conductor terminal in the control panel.
3. Before working on electrical components, make sure the system has been disconnected from all poles
and sources, and the generator has been stopped.
4. Secure the main switch with a padlock against unintentional re-closing.
5. Check electrical system for zero potential.
6. Never repair or short-circuit a fuse by means of a wire or any other item.
7. Immediately repair or replace all wires with defective isolation.
8. Do never bridge the system safety circuit except for system aligning by a qualified person.
5.2
MECHANICAL SYSTEM
WARNING !
1. Never service or repair any part or system component while the machine is operating.
2. Always disconnect the system from power before starting any maintenance work. Turn the main switch to
„0“ and padlock the switch to prevent unintentional re-closing. Stop the generating unit. Be sure to power
off the machine by yourself!
3. Before you start, make sure that all persons have left the operating range of the system.
4. Make sure no objects or vehicles are in or near the system tracks when system is starting to operate or is
actually running.
5. During system run, the towers shut on and off automatically. So keep a safe distance from the towers.
6. Never climb on the system while it is running.
7. Utmost care is required by the operator when spans are aligned.
8. Always turn off the system and stop water supply before working on sprinklers or spray nozzles.
9. Use adequate means of access (ladder, elevating platform) for work on sprinklers or spray nozzles.
10.Proceed with utmost caution, when system is working near or under electric power lines, so that neither
the metal structure nor the water jets of sprinklers get in contact with live wires.
11.When towing movable systems, make sure the system does not get in contact with a power line.
12.Make sure not to wet neighbouring plots or roads with the end gun. This could cause damage or accidents.
13.If fertilisers or other chemicals are added to the irrigation water, avoid mist and do not inhale it.
Operation Manual for BAUER LINESTAR 5000
6
6
TECHNICAL DESCRIPTION
6.1
COMPONENTS OF THE LINESTAR 5000
CENTRAL TOWER
Travelling central tower (rigid or swivable wheels depending on model) with linear control, diesel generator unit,
connection for water supply, control center.
SPAN
Arched truss consisting of the water-carrying pipes, the truss rods and V-Jack.
TOWER
Carries the span weight and provides the electromechanical drive of the system.
Components: wheel carrier, tower bracing angle, electrical drive motor, drive shafts, wheel gears and wheels.
TOWER COUPLING
Joint between the spans. Possible articulation: up to 30%.
ALIGNEMENT CONTROL
Electromechanical control system, that monitors the horizontal angular deviation between the spans and switches
the drive motors.
OVERHANG
Overhanging part from last tower to system end.
END GUN
Wide range sprinkler at the end of overhang for more spaying range
BOOSTER PUMP
Electric pump on the last tower for increase of pressure to end gun
Operation Manual for BAUER LINESTAR 5000
7
6.2
CENTER FEED – END FEED
6.2.1 Center feed
The central tower is located in the middle of the system and is part of the free-standing span.
6.2.2 End feed
The central tower is located at the end of the system being end tower as well.
Operation Manual for BAUER LINESTAR 5000
8
7
USE OF LINESTAR
7.1
LIMITS
7.1.1 Inclination
The maximum permissible inclination along the travel direction in linear mode for the central tower as well as for
the towers is 3,0°.
7.1.2 Permissibe bending angles
Maximum permissible inclination along the span is 3,0°.
Maximum difference in elevation between central tower and the first tower is 1 m!
Operation Manual for BAUER LINESTAR 5000
9
7.2
TRACK DETERMINATION AND MAINTENANCE
The determination of the track is extremely important, because it has an essential influence on the control of the
system.
 Track depth: max. 140 mm
 Track depth with swivable systems in rotating range: max. 100 mm
 Track of central tower: completely plain and free of ruts and grooves.
7.2.1 Travel direction
Before cultivating the crop and preparing the seed bed consider the following:
 Standard operation direction of the system is in a right angle to the crop rows.
 If the seed bed is deeper than 100 mm, it is recommended to make the system run parallelwise to the crop
rows.
If it is required to operate the system along the crop rows, apply one of the following methods to determine the
track.
Method I
1. Before cultivating make a „dry run “ along the entire field to fix the tracks.
2. Use these tracks as guidance for the crop row to be cultivated.
Keep a distance of 250 mm on both sides of the track for the first crop row.
Method II
1. Plant the entire field parallel to the system‘s travel direction.
2. Make a „dry run“ along the entire field.
3. Level out the crop rows 250 mm on both sides of the tracks. That way deep tracks and cracks between the
crop rows can be prevented.
An exact run of the system is guaranteed.
Instructions for determining tracks
1. Make a "dry run" with timer setting to 100 % over the entire field.
2. Then make a "wet run" with timer setting to 80 - 90 % over the entire field.
Then continue according to need.
If the tracks become too deep, they must be levelled out or filled up. Then make a dry run with timer setting to 100
% over the entire field. Return in wet run with the same timer setting.
Operation Manual for BAUER LINESTAR 5000
10
8
LINESTAR CENTRAL TOWER
8.1
FOUR-WHEEL CENTRAL TOWER
The central tower consists of the following components:
 Main frame with 4 rigid wheels (14.9-24)
 2 drive gear motors 0.55kW, drive of 4 wheel gear via cardan shaft
 2 supply connections with HK coupling in front
 Supply riser pipe DN 125, electrical shut-off valve
 STANDARD control center
 Linear guidance (furrow guidance or cable guidance)
 Diesel power generator according to system requirements 10kVA – 20kVA,
 Supply hose according to system capacity 3“ to 5“, or PE-pipe 90mm to 125mm.
At the field end the supply hose must be connected to the rear side of the central tower for the return run.
Operation Manual for BAUER LINESTAR 5000
11
8.2
TWO-WHEEL CENTRAL TOWER
Furrow guidance flipped up
Control center
Swivelling device
The central tower is towable.
The central tower consists of the following components:








Main frame with 2 electrically swivelling wheels
2 drive gear motors 1,1 kW, drive of 2 wheel gear via Hardy-Spicer universal joints
2 supply connections with HK coupling on the side
Supply rising pipe DN 125, electrical shut-off valve
Control center LINESTAR
Linear guidance (furrow guidance or cable guidance)
Diesel power generator 8kVA
Connecting hose depending on system capacity 3“ – 4“, or PE-pipe 90mm – 110mm.
For towing the machine the wheels of the central tower can be swivelled electrically. At the end of the field it is not
necessary to change the connection of the supply hose at the central tower for the return run.
Operation Manual for BAUER LINESTAR 5000
12
9
CONTROL CENTER
Design and material according to ÖVE and VDE standards, built-in components according to IEC standards and
VDE regulations.








ATTENTION!
Water-proof polyester box (protection IP 54) with lockable front door
Swivelling operating panel, can only be opened after turning off main
switch
Operating voltage 400 V
Control voltage: 220 V monophase
Isolating transformer for control voltage
Commercial contactors
Wiring with lugs
Protection devices
To protect against soiling and splash water always close the control panel during
operation.
4
1
3
2
5
6
Operation Manual for BAUER LINESTAR 5000
7
8
13
1. Main switch
2. Control panel Linestar Pro
3. Voltmeter
4. Hour meter
5. Switch Linestar ”OFF - ON“
6. Switch safety circuit „ON – OFF“
7. Switch End Gun “OFF - ON“
8. Switch Genset “OFF – ON”
9.1
Standard built-in components
1. Main switch
With the main switch the entire power supply is shut on or off.
In position "I" the electric power supply of the machine is established.
The hinged operating panel in this position is locked for safety reasons.
In position “0“ the power supply of the system is turned off.
In this position the main switch can be locked against unintentional switching on.
The hinged operating panel can only be opened in this switch position.
2. Control panel LINESTAR
2.1. Set-up / Main Components
2.1.1.
Display
2x16 alphanumeric LCD, with backlight. If no key is touched within a preset time, the backlight.turns off
automatically (adjustable backlight timer).
Operation Manual for BAUER LINESTAR 5000
14
2.1.2 Functions / Menu keys
START FORWARD (F)
Starts forward run (clockwise)
START REVERSE (R)
Starts reverse run (anti-clockwise)
MENU and ENTER
By pressing this key you get access to user level; it has got two more functions:
getting access to parameter programming mode and confirming the set data
(memorizing the parameter).
STOP (ESC and Machine)
This key stops machine run; it has got two more functions: getting access to expert
level and exiting programming mode (without memorizing the parameter).
.
+
Multipurpose key: to modify application rates and parameter settings
▬
Multipurpose key: to modify application rates and parameter settings
2.2. Switching on
2.2.1. Booting
After turning on the hardware LINESTAR will appear on the display as well as the installed software version with
loading date.
LINESTAR
V1.2 02/07/05
Fig 2.1: Display after turning on
After successful booting and initialising of the hardware the status window opens (see section 0).
2.3 Status window
The status window informs about the actual operation mode of the LINESTAR. After successful booting the status
window opens automatically. The displayed parameters are permanently updated. .
2.3.1 Status window
The status window (fig. 3.1) displays a two-column table informing about the actual operating mode. Please follow
the explanation here after.
ADVANCE
20 MM
50H/39MIN
LINEAR
Bild 3.1: Status window
Operation Manual for BAUER LINESTAR 5000
15
Operating mode
The following operating modes are displayed.

OFF
LINESTAR out of action

FORWARD
LINESTAR advances

REVERSE
LINESTAR returns

INTERMED:STOP
LINESTAR has reached intermediate stop

TRAVEL
LINESTAR is TRAVELLING

SAFETY
LINESTAR turned off because safety circuit responded

PRESS.STOP
LINESTAR turned off because water pressure is too low

START
LINESTAR waits for running out of start holding time, when pump is in action

WHEEL SWIVELLING
LINESTAR is in operation mode “wheel swivelling”

I2C FAILURE
Failure of 12C clock

ALIGNING
Manual aligning of LINESTAR and start into the opposite direction after automatic
shut-off
 SWIVELLING
The drive towers go around the central tower.
Remaining irrigation time
Display in hours and minutes of remaining time until end of program. If the LINESTAR is out of action, it displays
0H/0MIN. The calculated irrigation time will not comply with the real irrigation time because of rounding errors and
inexact machine parameters (especially of driving speed). If the LINESTAR finishes its program before the end of
the calculated irrigation time, the latter will be reset to zero. If the LINESTAR continues irrigation after the end of
the calculated irrigation time, the latter will also be displayed with zero, even though the LINESTAR has not
finished its program.
Application rate
When the LINESTAR is running, it displays the actual application rate for the actual travel direction, at standstill it
displays the latest application rate.
2.4 Parameter menu
By pressing the MENU key you get access to the parameter menu which consists of a series of windows. They will
be scrolled through by pressing the + and – keys, each window displaying 2 parameters.
Press the ENTER(Menu) key to get access to programming mode. The cursor at the first parameter starts
blinking. Set parameter with + and – keys. Use RIGHT ARROW (F) to move to second parameter. Use
LEFT ARROW (R) to return to first parameter. Press ENTER to memorize, press ESC to exit without
memorizing.
The functions of the different menu items are described here after.
2.4.1 Description of parameters
2.4.1.1 Mode
This parameter changes the actual operating mode
 LINEAR
Normal linear operating
 PIVOTING
End tower pivots around central unit
 WHEEL SWIVEL
Wheels of central unit and end tower (by option) respectively are swivelled
electrically
Setting range:
Press ENTER to change parameter. Press + – keys to change value, confirm value by pressing ENTER and exit
programming mode with ESC.
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2.4.1.2 Travel length
Irrigation length: This value is twice the length of the supply hose.
Setting range:
Press ENTER to change parameter. Press + – keys to change value, confirm value by pressing ENTER and exit
programming mode with ESC.
PRESS – KEY TO GET ACCESS TO NEXT PARAMETER BLOCK
2.4.1.3 Failure log
This menu displays the last 20 failures memorizing date and time.
If no failure has been memorized NO FAILURE will be displayed, otherwise you will be able to identify the failure
with the displayed text.
Scroll failure log with the RIGHT and LEFT ARROWS; the actual scrolling direction is signalled by the arrows
displayed in the left and right corner of the screen.
The latest failure is always displayed first when entering the failure log.
Failures are displayed as follows:
 NO FAILURE
No failures occurred so far, failure log is empty. No effect when pressing LEFT or RIGHT ARROWS
 SAFETY CIRCUIT
Safety circuit has been cut
Possible causes: emergency stop at control center has been actuated, doglegging or additionally mounted end
switch has been triggered.
 RTC ERROR
Real Time Clock error or I²C Bus error (repeated error warnings signal a hardware problem)
 . PRESSURE SWITCH
Water pressure is too low for set monitoring time.
2.4.1.4 Wet running hours
Displays running time in hours and minutes when operating with pump switched on.
Reset only when reloading preset parameters.
2.4.1.5 Dry running hours
Displays running time in hours and minutes when operating with pump switched off.
Reset only when reloading preset parameters.
2.4.1.6 Counter ENDT (end tower) and cycles
The item counter shows the actual timer reading of the end tower.
The first number displayed under the item cycles indicates the calculated running time of the end tower whereas
the second number shows the idle period of the end tower (in PIVOTING MODE).
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2.4.1.7 Counter ZE (central tower) and cycles
The item “counter” shows the actual timer reading of the central tower.
The first number displayed under the item “cycles” indicates the calculated running time of the system whereas the
second number shows the idle period of the system (in LINEAR MODE, applies to both end and central tower).
2.4.1.8 On Delay
Displays the actual timer readings in seconds.
2.4.1.9 Inputs, outputs
Displays all actual input and output signals
0 = no voltage at input 1 = voltage at input
0 = output off
1 = output on
2.4.1.10 Modem status signal level
This function concerns the signal level of the GSM Modems. Press the ENTER key to capture signal strength of
modem and to read it on the display. If the displayed value is higher than 15, machine control by SMS should be
possible.
2.4.1.11 COM READIN
Menu item concerning failure diagnosis of RS 232
2.5 Machine parameter menu
2.5.1 Description of different parameters
Press STOP key for 3 seconds to enter machine parameter menu.
Then the code menu should be displayed.
Use UP and DOWN arrows for setting code. Confirm with ENTER.
If code is right the text Machine Parameter Menu will be displayed.
CODE = 12
only for service technicians
CODE = 123
only for basic functioning settings
Press ENTER key.
PRESS
– KEY TO GET ACCESS TO FIRST PARAMETER BLOCK
PRESS + KEY TO GET ACCESS TO PRECEDING PARAMETER BLOCK
2.5.1.1 Date and Time
Setting of system date and system time
Press ENTER key to get access to programming mode.
The cursor is blinking at the actual day. Change value with + - keys.
Press right arrow to move cursor to month. Change value with + - keys.
Press right arrow to move cursor to year. Change value with + - keys.
Press right arrow to move cursor to time. Change value with + - keys.
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Press ENTER to memorize settings or ESC to exit programming mode.
PRESS
– KEY TO GET ACCESS TO NEXT PARAMETER BLOCK
PRESS + KEY TO GET ACCESS TO PRECEDING PARAMETER BLOCK
2.5.1.2 Language and irrigation width
To change set language, press ENTER key to get access to programming mode.
Change language with + – keys, press ENTER to memorize settings or ESC to exit programming mode, or press
RIGHT ARROW to move to irrigation width, change value with + – keys, press LEFT ARROW to return to
LANGUAGE; press ENTER to memorize settings or ESC to exit programming mode.
The irrigation width is the width in meters from central tower up to end tower, including overhangs.
2.5.1.3 Travel length and throughput
The travel length is twice the length of the supply hose in meters.
The throughput is the calculated or measured system throughput in m³/h.
These values allow for exact calculation of end tower cycles.
Change values according to above mentioned proceeding.
2.5.1.4 Time period and irrigation lag
The time period is the total of running time and idle period of the end tower.
Running time and idle period are calculated according to the set application rate. The total of running time and idle
period is always the time period.
The irrigation time lag is a delay in minutes for the motors after turning on the pumps to allow for irrigation under
full pressure from the beginning.
Change values according to above mentioned proceeding.
2.5.1.5 Pressure switch and pressure lag
Enter PRESSURE SWITCH ON to activate system pressure monitoring by the means of a pressure switch.
The PRESSURE LAG is the time in minutes the system is waiting, when pressure gets too low, before a pressure
FAILURE is displayed and the LINESTAR is stopped.
Change values according to above mentioned proceeding.
2.5.1.6 Maximum speed and display backlight
The MAXIMUM SPEED is a factor to calculate cycle duration depending on the set application rate.
This parameter is up to gearbox model, motor speed, tire size and soil conditions.
DISPLAY BACKLIGHT stands for the time for which the display will be backlit (if no time is set, backlight is
switched off).
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2.5.1.7 Phone number 1
Set phone number 1 to which all text-messages will be sent.
SETTING: When pressing the ENTER key the cursor goes to the first digit to be set. Enter the phone number
according to following pattern: type “+”, then the country code without the two zeros, then the area code and finally
the local phone number.
Use right arrow key to pass from digit to digit and use the + - keys to enter the digits from 0 to 9. Press STOP key
to exit the programme and memorize the phone number.
2.5.1.8 Phone number 2
Here you may set an optional phone number 2 to which all text-messages will be sent.
SETTING: Proceed according to 2.5.1.7
2.5.1.9 PIN, End Tower Automotive Moving
The PIN is the PIN CODE of the SIM card put into the GSM modem
IMPORTANT: Be sure to set the PIN CODE before you put the SIM card into the modem. Otherwise you would
have to set the PUK CODE by the means of a cell phone.
SETTING: Press ENTER, use + - keys to enter the 4-digit code, confirm with ENTER
End Tower Automotive Moving: This parameter concerns the machine MONOSTAR and is related to its optional
function “control for automotive moving of end tower”.
SETTING: Press right arrow key. Use + - keys to switch between OFF (LINESTAR) and. ON
(MONOSTAR): Confirm with ENTER.
2.5.1.10 Motoroffdelay, Type
Motoroffdelay: Prevents too rapid response of the linear control (switch debouncing)
SETTING: Press ENTER key, enter value with + - keys, confirm with ENTER.
Type: Select among machine type LINESTAR or MONOSTAR
SETTING: Press right arrow key, use + - keys to change from machine type LINESTAR to
MONSTAR and vice versa. Confirm with ENTER.
2.5.1.11 M (motor) running time and M (motor) correction
The MOTOR RUNNING TIME concerns only system adjustment by the means of the furrow guidance and here it
means the time one motor (of the central tower or of the end tower) must run before the second motor must be
turned on manually in order to eliminate mechanical stress in the system.
SETTING. Press ENTER key, enter value with + - keys and confirm with ENTER.
The MOTOR CORRECTION is the time for which the manually turned on motor will run after end of motor running
time.
SETTING: Press right arrow key, enter value with + - keys and confirm with ENTER.
2.5.1.12 Operator Delay, Motorsync
Operator delay is the key delay of the control pad.
SETTING: Press ENTER key, enter value with + - keys and confirm with ENTER.
Motorsync: Is not used
2.5.1.13 LCD Luminosity, Motor Delay
LCD Luminosity is the backlight intensity.
SETTING: Press ENTER key, enter value with + - keys and confirm with ENTER.
Motor delay is the delay after which the second wheel of the central tower gets started.
SETTING: Press ENTER key, enter value with + - keys and confirm with ENTER.
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2.5.1.14 SMS Central Number
Here you may manually set the number of the SMS central if the system has not identified it automatically.
SETTING: When pressing the ENTER key the cursor goes to the first digit to be set. Enter the phone number
according to following pattern: type “+”, then the country code without the two zeros, then the area code and finally
the local phone number.
Use right arrow key to pass from digit to digit and use the + - keys to enter the digits from 0 to 9. Press STOP key
to exit the programme and memorize the phone number.
2.6 SMS operated system
2.6.1 Receiving text messages with the Pro Controller
When connecting a GSM modem to the Pro Controller you are able to receive text messages with a standard GSM
cell phone.
These text messages concern either standard STATUS reports after a STOP or a START of the system or failure
reports for instance after a pressure loss or system misaligning.
Proceeding:
Switch on the Pro Controller.
Set the phone number and the PIN Code in the machine parameter menu.
Shut off the Pro Controller and connect the GSM modem to the Pro Controller.
Turn on the Pro Controller and watch initialization; finally the display must read GSM MODEM OK.
After successful booting a text message should have been sent to the set phone number. Now all SMS operated
functions of the Pro Controller are active (sending of failure reports, status messages or acknowledgements per
control SMS).
2.6.2 Controlling the Pro Controller per SMS
You can change the functions “STOP” or “change the precipitation rate” also per SMS.
Change precipitation rate per SMS (Text message)
In order to change the precipitation rate send a text message to the tel.no. of the SMS control modem,
containing
FWDxx or
RVWxx
!!!!!!! BE SURE TO WRITE ONLY CAPITAL LETTERS !!!!!!!
xx stands for the set application rate in mm.
xx always must be a two-digit value. If the application rate is less than 10, put a 0 first, that is write FWD05 if you
want the machine to move forward with an application rate of 5mm (longer texts will be ignored).
2.6.2.2 Stopping the Pro Controller by SMS
To start the Pro Controller send a text message to the phone number of the PRO GSM module, saying
STOP
2.6.2.3 STATUS request by SMS
To know the actual system STATUS send a text message to the phone number of the PRO GSM module, saying
STATUS
Return SMS of Pro Controller
Each SMS will be answered by a return SMS, reading:

Machine status (e.g.:forward)

Application rate forward and reverse in mm

System time

Remaining irrigation time
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2.7 Firmware update
1.)
2.)
3.)
4.)
5.)
6.)
7.)
Put the main switch of the control panel in position „OFF“
Open the inner door and connect the PRO-module to the laptop (PC or PDA) by the means of a serial cable
Turn the main switch in position „ON“ while pressing the MENU key (display reads: FLASH BOOTLOADER)
Start the programme „DownloadTool“
Select the right COM interface (if wrong interface display reads comerror)
Load the latest valid file with the browser (e.g. PercenttimerV3_3.hex)
START DOWNLOAD – files should be downloaded without interruption. After successful download display
reads Software Download successfully finished
8.) Cut the serial connection
9.) Turn main switch to „OFF“, press R+F simultaneously (version PRO), turn main switch to „ON“. Wait until
display reads load eprom. Now the standard parameters are loaded and the PRO starts booting.
2.7 Technical data
Control unit
Supply voltage
230 V/50 Hz (+/- 10 %)
or 12V -
Input
4 VA
Ambient temperature
0 up to 65 C
Dimensions (HxWxD)
85x90x75
Breaking capacity of the relays
230V~ 5A
Entries
230 V/50 Hz (+/- 10 %)
2.9 Connecting and wiring diagrams
Connect all inputs and outputs on backside with three plugs.
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3. Voltmeter.
Indicates the voltage between phases L1 and L2.
4. Operating hour meter
Counts the total operating hours of the machine
5. Switch LINESTAR “ON-OFF”
Establishes power supply of control center
6. Switch SAFETY CIRCUIT “ON – OFF”
If this switch has been put to position “ON”, the whole system will be shut down in case of malfunction
(misalignment). The position “OFF” is only to be used by an expert person for system alignment. Whenever the
machine is running the switch must be in position “ON” in order to guarantee a safe unattended run.
7. End gun “ON-OFF”
In position “ON” the end gun is in use, in position “OFF” it is out of use.
8. Switch “GENERATOR OFF - ON“
The generator unit shuts down automatically.
ON





OFF
when system runs into safety circuit.
in case of pressure loss in supply line
at end stop
at intermediate stop, e.g. when changing the connection of the supply hose.
Use this setting for regular run!
In this position the generator unit does not shut down automatically for the above mentioned reasons.
This setting is used for:
 aligning the LINESTAR.
 dry run of LINESTAR
9. Switch „EMERGENCY STOP“
Control unit is cut off power.
.
8
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10
LINEAR CONTROL SYSTEM
The LINESTAR is guided along a furrow in the ground (FURROW GUIDANCE), or along a guiding cable (CABLE
GUIDANCE).
The linear control system mounted at the side of the central tower controls both end towers.
This control system allows the system to run always parallel to the control furrow or to the guiding cable.
Two control rollers transmit the distance and the angle of the central tower to the furrow or the cable to the
correction control.
The linear control system consists of two control units, the one at the front (looking into travel direction) being
always responsible for the control of the system and controlling the operation of the electric drive motor of the end
towers.
10.1 FURROW GUIDANCE
Max. deviation of the straight line
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Permissible curve radius of control furrow
SL....System length of LINESTAR
R......Permissible curve radius
10.2 CABLE GUIDANCE INSTALLATION AND ADJUSTMENT
1. The Cable Guidance system consists of an above ground cable that is supported by a line of pipe posts which
are placed every 6 m. For installation be sure to observe the following two conditions:
A. The posts must be located in a perfectly straight line.
B. The cable must be properly tensioned.
Clip
6m
End post
Post
Cable
0,6 m
End post
6m
Length of field
2. Posts: The posts must be paralleled to the ditch (ditch feed) or to the track of the central tower (hose feed)
respectively.
They must be placed every 6 m in a straight line. The last posts at the end of the field must be solidly embedded in
the soil by ground anchors to withstand the cable tension.
.
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Cable
Clip
Post
3. Cable
The Cable is attached to the posts by the means of clips welded onto the posts.
Attach one end of the cable to the end post with a thimble and three clips. Five meters before the opposite end of
the cable attach a second, 10 m long cable to the main cable with three clips. Fasten the end of this second cable
to a vehicle or a tractor and pull until the cable is well tensioned. Recommended cable tension: approx 4000 N.
After tensioning fasten the main cable to the end post and remove the auxiliary cable.
Cable clamps
Second cable
To vehicle
Main cable
End post
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10.3 SETTING LINEAR CONTROL
Before starting, adjust the linear control system such that the central tower will run parallel to the guiding cable or
to the guiding furrow in both directions.
The setting of the switch points for furrow and cable guidance is basically the same.
skid or cable roller



Position the central tower in relation to the cable or the furrow in such a way, that both control arms, when they
are in their operating condition (rollers on the cable or in the furrow) form a straight line with the fixed control
frame of the central tower.
Loosen the fixing screw on the control rod, which actuates the control cam of the control system. The control
rod moves freely on the guide pin.
By moving the control rod hence and forth, the switching points of the micro-switches are determined. Every
micro-switch has two switching points, a switch-on point and a switch-reverse point. Each of these switching
points is marked on the guiding pin. Fix the switching points according to the following figure:
Operation Manual for BAUER LINESTAR 5000
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

If the distance between the end switching points of both micro-switches is too small or too great, readjust the
position of the micro switches and verify the distance between the switching points.
If the distance between the switching points is correct, the control rod must be fixed exactly in the center
between the switching points.

Set the second linear control system the same way.
10.4 SETTING STOP SWITCH
There are switches on the central tower of the LINESTAR, which stop the system.
To activate these switches, actuation pegs must be provided along the track.
The following switches must be mounted:
 End stop
Safety switch at the end of the field, which shuts down all functions.
 Intermediate stop
 Stops the system for instance between two hydrants to allow changing the hose connection. Adjust the stop
levers for the end stops in such a way to make them surely actuate the end stop switch.
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CABLE GUIDANCE
ACTUATE ENDSTOP
ACTUATE INTERMEDIATE STOP
FURCHENSTEUERUNG – Schalteranordnung
FURROW GUIDANCE – switch arrangement
Intermediate
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11 DIESEL GENERATOR UNIT
For the supply of the electric drive and control system of the LINESTAR a diesel generator unit is mounted
on the central tower. Depending on the power requirement of the system the electrical power of the unit is
between 10kVA and 20kVA.
The unit is complete and consists of the following components:
 Base frame with integrated fuel tank.
 Diesel engine with electric start including battery
 Generator directly coupled to the engine.
 Unit cover
 Unit control panel with following functions and indications:
Three Ampere indicators (one per phase)
One voltmeter with phase converter
Frequency indicator
Operating hour meter
Luminous indication of malfunction
Failure indicator for oil pressure, cooling water temperature, battery charging, fuel,
Warning siren
Fuses
Start lock with key
Stop switch
12
ALIGNMENT OF THE LINESTAR
12.1 ALIGNING THE CENTRAL TOWER PARALLEL TO THE LINEAR GUIDANCE
(FURROW, CABLE)
Zentraleinheit
Central tower
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Align spans at right angle to the central tower (the imagined connection between the tower motors must be an
exact straight line)
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13
ALIGNMENT CONTROL
An alignment control is mounted on every tower
(between every span).
The alignment control ensures the straight run of the
LINESTAR.
Every angular deviation between the different spans is
transmitted by a shift linkage and a control cam to the
microswitches, which turn the drive motors on and off
and keep the system perfectly aligned. One microswitch
is the operating switch, another one a safety switch,
which shuts the system off in case of a too heavy
doglegging.
In addition to the microswitches an RC-link is mounted,
which compensates voltage peaks to protect the
switching devices.
The exact adjustment of the switching devices is absolutely necessary for the proper functioning of the machine.
Each alignment control leaves the manufacturer’s in adjusted and tested condition.
Operating voltage 400 V, control voltage 220 V/50 Hz.
13.1 MICROSWITCH ADJUSTMENT
If a new microswitch (control – or safety switch) has been
mounted into an alignment control, it must be set into the proper
operating position. For mounting works imperatively power off the
entire machine. Detach the electrical connections, remove the
defective switch and replace it by a new one. Reattach the
electrical connections. Adjust the microswitch as follows:
1. Unwind the switch fixing screw.
2. Control switch: twist the switch cam until the switch roller touches notch „A“. Move the switch in the bolt
holes towards the switch cam until the control switch (microswitch) responds (clicks), the bracket of the
switch lying next to the switch housing. Fix the switch with the screws in this position.
3. Safety switch: twist the control cam until the switch roller touches notch „B“. Move the switch toward the
cam until it responds (clicks), the bracket of the switch lying next to the switch housing. Fix the switch with
the screws in this position.
4. Check the switching points, repeat adjustment if necessary.
A periodical check and re-adjustment (if necessary) of the exact switching points of the micro-switches is obligatory
to guarantee a trouble-free operation of the machine.
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14
ELECTRICAL SYSTEM
WARNING !
System is powered by 230 Volts and 400 Volts (460 Volts) !
All installation and service work must be performed with extreme care by
an expert person - in strict compliance with the relevant safety codes !
WARNING !
All electrical installation to be carried out ONLY after powering off the
complete system!
14.1 CABLES AND MARKINGS
1. The pivot cable consists of 11 phases which are marked by colours.
Phase colour
Power circuit
Control circuit
Grounding conductor
Black
Blue
Brown
Pink
Grey
Red
White
Violet
Green
Orange
yellow/green
Phase number
1
2
3
4
5
6
7
8
9
10
2. Cable lengths
The cables are already cut to length and stripped at their ends at the manufacturer’s.
Cables are long enough to enter the alignment controls in a slight loop.
3. Mounting the cables
On the tower side of the span, where the alignment control has been mounted on the end pipe, the cable end
is placed along the pipe up to the end of the pipe, where it is fixed with the spring clip. Now the cable ends
have got the right mounting length on both sides.
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14.2 INSTALLATION, CONNECTION OF CONTROL CENTER
WARNING !
Be sure to power off the supply line before connecting the control center or
performing any installation works on the electrical system!
1. Put the cable into the control center and connect it to the terminal strip according to the wiring diagram.
2. Connect the three phase conductors of the connecting cable according to wiring diagram. (Make sure the
magnetic field turns to the right, use a rotating field meter. In case of negative phase sequence, change 2 phase
conductors of the connecting cable against each other at MAIN SWITCH Q1).
3. Tighten cable threads at box entry to protect of water
14.3 ALIGNMENT CONTROL CONNECTION
1. Feed 3 cables into the alignment control:
incoming feeder cable,
forwarding of feeder cable,
cable to the tower drive motor
2. Connections according to the enclosed wiring diagrams.
4. Distinguish between different alignment control options.
NOTE !
Correct wiring of all alignment controles is essential. If phases are muddled up the
towers travel into different directions!
5. Connect both coupling parts of the spans to the grounding.
6. Tighten cable threads at box entry to protect of water.
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15
FIRST START-UP
15.1 CHECKING OF CENTRAL UNIT

Are all screws well tightened?

Proper wiring of control center?
Check circuit continuity according to flow sheet with a continuity tester.

Are pipe clips of the connecting hoses of riser pipe fastened properly?

Is the fixing ring fitting tightly the bearing pipe and is it well screwed ?

Are the wheel nuts well tightened? (tightening torque 130 Nm)

Tire pressure:
1,5 bar for tire size 14.9 – 24
2,1 bar for tire size 11.2 – 24
0,8 bar for tire size 16.9 R 24

Are wheel gears and drive motors filled up with oil? (see points 15.3.1 and 15.3.2)
15.2 CHECKING OF TRUSS, END TOWER AND OVERHANG








Are all screw connections well tightened? (Flange screws with 100 Nm)
Are all wheel nuts well tightened? (Tightening torque 130 Nm)
Tire pressure:
1,5 bar for tire size 14.9 – 24
2.1 bar for tire size 11.2 – 24
0.8 bar for tire size 16.9 R 24
Are wheel gears and drive motors filled up with oil?
Are electric cables properly fastened?
Are cable inlets water tight?
Are sprinklers and nozzles properly installed according to delivered computer table?
Are all overhang ropes fastened properly?
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15.3 GEARBOXES AND DRIVE MOTORS
15.3.1 Gearboxes
Worm gear with 50:1 reduction ratio.
Model :
for stationary systems
for towable systems with freely rotating hub
Used oil quality :
Oil quantity approx.:
SAE 85W-140, multigrade oil
3.8 litres up to bottom edge of filling hole
oil expansion is compensated by expansion membranes
TNT Gearbox
TNT wheel gears have got two grease zerk fittings to lubricate the shifting device (cf. figure hereafter). We
therefore underline that the gears need to be lubricated before the first putting into operation of the machine as well
as once or twice per season depending on how often the machine has to change place. Use Lithium based grease
(e.g. CASTROL Grease LMX or SHELL Retinax LX2). After greasing actuate the shifting handle repeatedly to
ensure uniform spreading of grease.
Ausrückhebel
Shifting handle
Schmiernippel
Grease zerk fittings
15.3.2 Drive motor
Spur gear with 40:1 reduction ratio, optional 30:1
Standard output 0.55 kW; optional 1.1 kW
Travelling speed with tires 14.9-24:
Used oil quality
:
Operation Manual for BAUER LINESTAR 5000
ratio 40:1
ratio 30:1
= 144 m/h
= 193 m/h
SAE 50W, or SAE 20W-50 multigrade motor oil
36
Oil quantity:
approx 3.8 litres up to bottom edge of filling hole
15.4 CONTROL CENTER
WARNING !
All work on the electrical control system is to be done by a qualified electrician !
All metal components of the system must be properly grounded with a yellow/green
protective conductor !
The protective conductor must be connected to a suitable earthing (according to
local legislation).
15.4.1 Checking voltage and wiring
1. Check supply voltage by measuring.
3-phase alternating current :
380 V / 400 V +/ 5% / 50 Hz +/ 2%
or as alternative: 460 V +/ 5% / 60 Hz +/ 2%
2. Check the control voltage on transformer (L11, N11). 230 V +/- 5%
15.4.2 Checking tower travel direction
- Start generator unit
- Turn main switch to position “1”
- Turn „LINESTAR“ switch to “ON”
- Turn safety circuit switch to “OFF”
WARNING !
In the “OFF” position, the "SAFETY CIRCUIT" switch deactivates the safety
system.
Control panel
- The control panel displays mode “ALIGNING”.
- Press "FORWARD" key
- Press + - keys simultaneously and hold the keys. The Linestar must start to move clockwise.
- Press "REVERSE" key.
- Press + - keys simultaneously and hold the keys. The Linestar must start to move anti-clockwise.
- In case of faulty run of the system release the + – keys immediately!
- In case the travel direction of the wheel pairs of the central tower do not harmonize, shut off of electric power
supply and change 2 phases of the feeding cable on the main switch.
- If none of the towers starts correctly into the set travel direction, shut off of electric power supply and change 2
phases of the feeding cable on the main switch
Operation Manual for BAUER LINESTAR 5000
37
- If only individual towers travel into the wrong direction, shut off of electric power supply and reverse the poles of
the motor supply cable at the concerned tower.
15.5 ALIGNMENT OF THE TOWERS
If the system is not precisely aligned after mounting, i.e. the assumed connecting line of all drive motors does not
form a perfect straight line, the system needs to be aligned as follows:
15.5.1 Control Center Linear Pro
NOTE!
In order to prevent a mechanical overload of the truss, align the Linestar step by step
starting at the system end. The assumed line connecting all tower motors with the
middle of the central tower must be perfectly straight.
- Start generator unit
- Turn main switch to position “1”
- Turn safety circuit switch to “OFF”
- Turn „LINESTAR“ switch to “ON”
Control panel
- The control panel displays mode “ALIGNING”.
- Press "FORWARD" or "REVERSE" key to select travel direction
- Press + key. As long as the + key is hold the end tower is moving. .
- Press - key. As long as the - key is hold the central tower is moving.
- Press + - keys simultaneously to make run both central tower and end tower. They will continue to move as long
as the +- keys are hold.
- Align the towers by the tower alignment switches to make them form a straight line with the middle of the central
tower (aiming over drive motor).
NOTE!
In order to prevent a mechanical overload of the truss, align the Linestar step by step
starting at the system end. The assumed line connecting all tower motors with the middle
of the central tower must be perfectly straight.
15.6 ALIGNMENT CONTROL ADJUSTMENT
ATENTION!
Make sure that the main switch is in position „0“ Lock the switch against unintentional
re-closing or lock the door of the control box.
First of all the system must be perfectly aligned before the adjustment of the alignment control is to be started.
Then adjust the switch cam by winding the screws on the threaded rod until the roller of the control switch is
touching notch „A“ just in the middle between the switching point and the reversing point (in between both clicks).
This guarantees the same control angles in FORWARD and REVERSE run.
Operation Manual for BAUER LINESTAR 5000
38
Adjust the microswitches as follows:
1. Twist the control cam by turning the hexagonal nut on the threaded rod until the
control switch touches notch „A“ and responds.
2. Rotate the control cam clockwise up to the reversing switch point (click) of the
control switch, count the number of rotations of the nut or the turns with the
wrench.
3. Wind back the control cam by half of the counted nut or wrench turns to make the switch roller rest exactly in
the middle between switching and reversing point of the control switch.
4. Fix the adjustment nut with the lock nut on the threaded rod.
Adjust the two other nuts in such a way to preload the spring by
about 10 mm.
Operation Manual for BAUER LINESTAR 5000
39
15.7 CHECKING ALIGNMENT
The LINESTAR is best aligned, if the system is forming a slight regular forward bow in both travel directions.
If this is not the case, realign the system as follows:
- Turn main switch to position “1”
- Start generator unit
- Turn safety circuit switch to “ON”
- Turn „LINE9STAR“ switch to “ON”
Control panel
- Press Enter key (Menu), the cursor starts blinking
- Press +- keys to set „Linear” mode
- Confirm with Enter key
- Press ESC to exit programming mode
- Press „Forward“ key. The LINESTAR must start to move clockwise
- Press + key to set a high application rate
Check if the driving motor of the first tower is located in front of an assumed line connecting the drive motor of the
second tower and the middle of the central tower. If this is not the case, the alignment control on the first tower
must be readjusted as follows: Unwind the hexagonal nuts and twist the threaded rod until the above requirement
is fulfilled.
The next step is to check if the drive motor of the second tower is positioned in front of an assumed line
connecting the drive motor of the third tower and the middle of the central tower. If this is not the case, correct the
alignment control on the second tower.
Now check all the towers step by step as described under a) and b) Re-adjust alignment controls if necessary.
Finally the LINESTAR should form a positive bow, which means that the towers in between end tower and central
tower must be positioned in front of an assumed line between end tower and central tower.
- Press „Stop“ key
- Turn main switch to position „0“
16
TERMINOLOGY
Forward
Looking from the central tower to the system, the LINESTAR moves to the right.
Reverse
Looking from the central tower to the system, the LINESTAR moves to the left.
Inward
Direction central tower
Outward
Direction last tower
Positive bow hurrying ahead
If the middle towers are in front of an assumed straight line in travel direction between central tower and end tower.
Negativer bow hurrying backward
If the middle towers are behind an assumed straight line in travel direction between central tower and end tower.
Dogleg
Happens, when a tower gets slower or stands still or hurries ahead of the other towers.
Operation Manual for BAUER LINESTAR 5000
40
17
START-UP
The LINESTAR is only to be released for operation to the customer after it has been completely assembled,
installed and successfully started up by a qualified person!
As the machine is operated with voltages from 200 V up to 460 V, the control components and the electric drive
need to be handled with the utmost caution! Service and repair works must imperatively be done by a professional
electrician!
Before starting the system make sure, that all connected devices (like generator and pump units) are ready for
operation. Have the responsible service center repair possible damages, before you start irrigating. Be extremely
cautious with live parts.
The start-up as described below is valid for a BAUER LINESTAR without optional equipment. If the system has got
any optional equipment (see chapter options), it has to be set properly and turned on before the start-up.
17.1 Start Linestar in operating mode “Linear”
17.1.1 Start Linestar with hose feed
- Connect supply hose to hydrant and central tower, open water supply
- Put switch Genset „OFF – ON“ to „OFF“
- Start generator unit
- Turn main switch to „1“
- Put switch Linestar „0FF – ON“ to „ON“
- Put switch Saftey Circuit „ON – OFF“ to „ON“
- Put switch End gun „OFF – ON“ to ON
Control panel
- Control panel
- Press key “Enter (Menu)“, the cursor starts blinking
- Select mode “Linear” with + - keys.
- Press „Forward“ key to go to parameter travel length, set travel length with + - keys
- Confirm with „Enter“ key
- Exit programming mode with „ESC“ key.
- Press „Forward“ or „Reverse“ key depending on running direction
- Modify application rate with + - keys.
- Put switch Genset „OFF – ON“ to „ON“
17.1.2 Start Linestar with ditch feed
BEFORE PUTTING INTO OPERATION
Check diesel engine for:
- quantity of motor oil
- quantity of fuel
- quantity of cooling water
- clogged air filter
Vacuum pump
- fill in oil
- check if sealing rubber of the safety tank fits tightly.
Operation Manual for BAUER LINESTAR 5000
41
PUTTING INTO OPERATION
 Turn switch „Genset OFF-ON“ to “OFF”
 Put pump out of operation by disengaging clutch
 Start diesel generator unit
 Turn main switch to position „1“
 Turn switch „SAFETY CIRCUIT ON – OFF“ to position „ON“
 Turn switch „LINE STAR OFF-ON! to position „ON“
 Put switch “End gun OFF – ON” to “ON”
 Submerge suction pipe with floats into the water until it is completely covered.
 Open ball valve in suction line of vacuum pump.
 Close gate valve in pressure line
 Put vacuum pump into operation
 Suction until pressure on pressure gauge increases to 2 bar
 Put pump into operation by engaging clutch
 Slowly open the valve gate in the pressure line, pressure must not drop below 1.5 bar
 Close ball valve in the suction line of the vacuum pump
 Cut off vacuum pump
Note!
Do not put LINESTAR into operation before the system is completely filled with water!
Control panel
- Press key “Enter (Menu)“, the cursor starts blinking
- Select mode “Linear” with + - keys.
- Press „Forward“ key to go to parameter travel length, set travel length with + - keys
- Confirm with „Enter“ key
- Exit programming mode with „ESC“ key.
- Press „Forward“ or „Reverse“ key depending on running direction
- Modify application rate with + - keys.
- Put switch Genset „OFF – ON“ to „ON“
Note!
If the system has got a low pressure cut-off, the full operating pressure must be
established inside the pipe system within a predefined time (setting at pressure gauge),
otherwise the security system will get released.
Make sure the control centre is tightly closed to protect it from soiling and splash water.
Check tightness of the pipe net, stability of operating pressure and power supply always when system is running.
17.2 Starting after intermediate stop
It may be necessary to stop the LINESTAR somewhere along an irrigation strip, for instance if the supply hose
needs to be connected to another hydrant or if only a partial area has to be irrigated.
In this case a shut-down sensor is actuated by a switching peg and the machine is turned off.
The shut-off valve in the riser pipe (option) is closed and the generator unit is shut down, when the switch
GENERATOR UNIT STOP has been put to ON.
Control panel
Operation Manual for BAUER LINESTAR 5000
42
- Press “Forward” or “Reverse” key
The machine must leave the switching range within 30 seconds, otherwise it will be shut off automatically.
17.3 Shut-down procedure
17.3.1 System shut off during irrigation
Control panel
- Press “Esc – Stop” key
If the switch GENSET “OFF-ON” has been turned to”ON”, the generator unit shuts down automatically. If the switch
has been turned to “OFF”, the generator unit must be turned off separately. Water supply will be cut automatically
by the shut-off valve.
17.3.2 Automatic system shut off at field end
The switches of the central unit shut the LINESTAR automatically down, when they are actuated by the end
stoppers which have been placed at the end of the field.
If the switch GENSET „OFF – ON“ has been put to „ON“, the generator unit shuts down automatically. If the switch
has been turned to „OFF“ the generator unit must be shut down separately
The water supply is cut automatically by the shut-off valve
17.4 Starting LINESTAR to run in opposite direction after an automatic shutdown
- Put switch GENSET „OFF – ON“ to „OFF“
- Start generator unit
- Establish water supply
- Put switch “Safety Circuit “ON-OFF” to “OFF”
Control panel
- The control panel displays mode”Setting”
- Press the “Forward“ or „Reverse“ key to select travel direction
- Press and hold the + - keys simultaneously until the machine has left the switching circuit
- Put switch “Safety Circuit “ON-OFF” to “ON”
Control panel
- Press „Forward“ or „Reverse“ key to start the machine
- Put switch GENSET „OFF – ON“ to „ON“
Operation Manual for BAUER LINESTAR 5000
43
17.5 Starting the LINESTAR in operating mode „Wheel swivelling”
Conditions:
- The central tower must be positioned directly above the swivelling point.
- The swivelling range must be clear of weeds or obstacles.
- The tracks which are to be crossed must not be deeper than 100 mm.
- Remove guidance cable from clips around towers (cable guidance)
- Disconnect supply hose from central tower.
- Flip up skids of furrow guidance and attach to central tower.
- Put switch GENSET „OFF – ON“ to „OFF“
- Start the generator unit
- Turn main switch to position „1“
- Put switch Linestar „OFF – ON“ to „ON“.
Control panel
- Press „Enter (Menü)„ key, the cursor starts blinking
- Select mode „Wheel swivelling“ with „+ - „keys
- Confirm with „Enter“
- Press „ESC“ to exit programming mode
- Detach fixing device of drive console at wheel carrier.
- Press one of the arrow keys to see which one of the motors gets started.
- Press arrow keys „(Forward-Reverse) to swing concerned wheel by 90°.
- Fix wheel with wheel brace.
- Press both arrow keys of control box simultaneously to skip to second motor.
- Press arrow keys of control box to swing second wheel by 90°
- Fix with wheel brace.
- Remove driving pin of gearbox (freewheel).
Operation Manual for BAUER LINESTAR 5000
44
17.6 Starting the LINESTAR in operating mode „Pivoting“
- Connect supply hose to hydrant and central unit.
- Flip up skids of furrow guidance and fasten them on the central unit
- Put switch “GENSET OFF” – ON to „OFF“.
- Start the generator unit.
- Put main switch to „I“.
- Put switch „Linestar OFF – ON“ to „ON“.
Schwenkeinrichtung
Swivelling device
- Swivel central unit wheels according to point 17.5
- Lower pivoting device (hydraulic stand) by means of hydraulic hand pump
- Establish water supply
Control panel
- Press key „Enter (Menu)“, the cursor starts blinking.
- Select mode “Pivoting” with + - keys.
- Confirm with „Enter“.
- Exit programming mode with „ESC“.
- Press “Forward“ or „Reverse“ key depending on travel direction
- Change application rate with + - keys.
- Put switch “GENSET OFF – ON“ to „ON“.
Operation Manual for BAUER LINESTAR 5000
45
17.7 Shut down procedure
17.7.1 LINESTAR shut down during irrigation
- Control panel
- Press “ESC – Stop“ key
If switch GENSET „OFF – ON“ has been put to „ON“, the generator unit shuts down automatically. If the switch has
been turned to „OFF“ the generator unit must be shut down separately. The water supply is cut automatically by
the shut-off valve.
17.7.2 Automatic shut-off of LINESTAR
A switch mounted on the tower shuts down the LINESTAR automatically, when it is actuated by a shut-off bar
which has been placed at the end of the field (optional equipmebnt).
If the switch “GENSET OFF – ON“ has been put to „ON“, the generator unit shuts down automatically. If the switch
has been turned to „OFF“ the generator unit must be shut down separately
The water supply is cut automatically by the shut-off valve
17.7.3 STARTING INTO OPPOSITE DIRECTION AFTER AUTOMATIC SHUT-DOWN OF
LINESTAR
As described in chapter 17.4
18
MAINTENANCE INSTRUCTIONS
Note
Guarantee claims can only be processed if the regulations concerning handling, maintenance (according to service
plan) and care have been observed. All service works must be carried through by an authorised dealer and they
must be confirmed in the service plan. The service plan is considered as evidence for warranty claims.
The meaning of the service plan
The service plan stipulates the time and kind of service. In the evidence spaces we confirm the carrying out of the
service which can be a condition for possible warranty claims.
We kindly ask you to understand that normal wear and tear as well as damages due to overstrain, improper use or
unauthorized modifications are excluded form this guarantee.
- Always cut power before starting any maintenance work on the system. Turn the main switch to “0“ and lock the
switch to prevent unauthorised or unintentional re-closing of the system. Always cut power supply by your own.
- Be sure to re-install all protective devices which have been dismounted during maintenance.
18.1 SERVICE INTERVALS
-
Monthly service
Annual service
Operation Manual for BAUER LINESTAR 5000
46
Extent of Service
Central tower
- Check all screwed joints
- Check tightness of electric cable entries into the control center
- Check tightness of connecting hoses in the riser pipe
Annual
maintenance
Intermediate
maintenance
18.2 SERVICE PLAN
X
X
X
X
X
X
X
X
X
X
Trussing, overhang, coupling
-
Check all screwing on flanges, truss rods, braces, on towers and on overhang
Check tightness of connecting hose at tower couplings.
Lubricate ball joint of tower couplings
Empty sand trap
Booster pump – spinning of shaft between engine and pump – check if pump rotor rotates
freely (if existing)
Check end gun (if existing)
X
X
, transmission
-
Check switch cam and adjust if necessary
Check shifting travel of micro switches
Check function of micro switches (operation switch and safety switch)
Check all electric connections for contact
Check tightness of all cable entries into the alignment control
Check tightness of alignment control covers
Lubricate the ball joints at transmission parts
Exact control – Check tension of guiding cables
Visual inspection of span alignment
-
Check function of switches for intermediate stop, end stop and of programme switch
-
Operation Manual for BAUER LINESTAR 5000
X
X
X
X
X
X
X
X
X
X
X
X
X
47
-
Lubricate cardan joints
Check easy moving of guiding rollers of cable guidance
Check distance and parallel moving of central tower with respect to furrow or cable
control
- Check straightness of guiding cable or furrow
Drive unit
- Check oil level of wheel gears and drive motors
- Change oil after first irrigation season, then every third irrigation season
- Wheel gear: Make sure the drainage holes on bearing covers and the vent hole of the
expansion chamber are not clogged
- Wheel gear Type TNT – Lubricate shifting device
- Drive motor: Make sure the drainage hole at bottom side of the motor is not clogged.
- Wheel gear, drive motor - check tightness of shaft sealing rings
- Lubricate freewheel hubs of towable wheel gears
- Check screw connections of driveline couplers
- Check if rubber packages of driveline couplers are damaged. Replace worn and broken
rubber packages.
- Check wheel nuts
- Check tire pressure:
1.5 bar with tires 14.9 – 24
2.1 bar with tires 11.2 – 24
0.8 bar with tires 16.9 – 24
- Make sure tires are not damaged
- Check anti-twist protection of drive shaft cover
Generator unit
- see separate motor manual
Operation Manual for BAUER LINESTAR 5000
Annualmaintenance
Intermediate
maintenance
Extent of Service
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
48
18.3 POST-SEASON MAINTENANCE
1. Remove the drain valves and plugs in the pipeline.
2. Open gate valve of sand trap.
3. Flush the pipelines.
4. Remount and close drain valves, plugs and gate valves at sand trap.
5. Remove the supply hose from the irrigation field and stock it in a building.
6. Provide a weatherproof cover for the positioning control on the central tower.
7. Empty the coolant of the generator unit or care for sufficient anti-freeze.
18.4 PRE-SEASON MAINTENANCE
1. Check control center and alignment controls for damages due to oxidation, rodents and insects.
2. Open sand trap gate valve and flush pipelines.
3. Check tightness of flange seals and connecting hoses.
4. Close sand trap gate valve.
5. Tension cable for cable guidance and align pegs
6. Draw a new furrow for the furrow guidance
7. Place and align the pegs correctly for intermediate stop and end stop
8. Unwind supply hose and check if it is still waterproof
9. Fill in or add coolant into the generator unit. Check motor oil.
10. Further checks => CHECKLIST
Operation Manual for BAUER LINESTAR 5000
49
18.4.1 Preload forces and tightening torques of bolts
The listed preload forces and torques concern
- standard metric threads according to DIN 13
- bolt head bearing faces according to DIN 912, 931, 934, 6912, 7984 and 7990
- coarse inch threads (UNC)
- fine inch threads (UNF)
and assume a bolt deformation limit of 90° and a friction factor of 0.14 (new bolt, no finishing, unlubricated).
Bolts with standard metric thread DIN 13
dimension
M8
M 10
M 12
M 14
M 16
M 20
M 24
quality
8.8
8.8
8.8
8.8
8.8
8.8
8.8
torque
preload force
Nm
N
25.5
50
87.3
138.3
210.8
411.9
711
16230
25791
37657
51681
71196
111305
160338
Bolts with standard UNC thread
dimension
1/4"
5/16"
1/2"
quality
S
S
S
torque
preload force
Nm
N
12.5
21.3
92.7
10080
13954
38463
Bolts with standard UNF thread
dimension
9/16"
quality
S
torque
preload force
Nm
N
150
57143
When mounting the wheel gears never use an impact wrench for tightening the 1/2" UNC bolts.
You risk damaging the thread inside the gearbox.
Operation Manual for BAUER LINESTAR 5000
50
19
TROUBLESHOOTING
FAILURE
System shut down
automatically:
a) power generating unit
System running in safety
circuit
POSSIBLE CAUSE
low fuel
battery low
loose terminals
low coolant
low oil pressure
loose V-belt
doglegging
faulty system alignment
Abnormal motor or gearbox
noise
System does not start up
microswitch defective
obstacle in the track
intermediate stop switch has been
actuated
leakage-current relay triggered by short
circuit to system
low oil level
oil worn
defective bearing
main switch turned off
safety disconnect Q1 turned off
fuses of fuse switch disconnector
defective
fuses F1, F2, F3, F4 defective
REMEDY
refuel
recharge
tighten
fill up
soiled oil filter
fill up lube oil
tighten
see Restart after doglegging
correction by trained
service staff
replace microswitch
remove obstacle
adjust stop bracket properly or
remove obstacle
reset leakage-current relay
(blue reset button)
add oil
change oil
replace bearing
turn it on
turn it on
replace defective fuses
replace defective fuses
safety circuit interrupted because system see “Restart after doglegging”
flex larger than maximum permissible
bending angle
A certain tower always runs
inside the safety circuit
In forward and backward run
the central tower is keeping a
different distance to the
cable/furrow guidance
no water pressure
(only with low-pressure shut-off option)
Wrong microswitch setting in the
alignment control
microswitch defective
contactor defective
cable loose
check water supply
readjust pressure switch
readjust microswitch
tower slips
thermal protection (inside motor) has
responded because of:
obstacle in the track
deep soil
low oil in wheel gear
The micro switches of the linear control
are adjusted differently
level the track
Operation Manual for BAUER LINESTAR 5000
replace microswitch
replace contactor
check connections and tighten
if necessary
remove obstacle
fill up and level the track
add oil
Adjust micro switches in both s
51
19.1 RESTART AFTER DOGLEGGING
NOTE!
WARNING!
Before carrying through the below mentioned operations be sure to rectify the cause
of doglegging (cf. chapter Troubleshooting).
In the “OFF” position, the "SAFETY CIRCUIT" switch deactivates the safety system.
Only permitted for service works.
- Put switch Safety circuit „ON – OFF“ to „OFF“
- Put switch LINESTAR „OFF – ON“ to „ON“
Control panel
- The control panel displays mode “Aligning”
- Press Forward or Reverse key to select the travel direction which is necessary to bring the outer spans back to
form a straight line with the system.
That is:
the outer doglegging towers hurry ahead: press the „Reverse“ key.
the outer doglegging towers lag behind: press the „Forward“ key.
- Press and hold the „+“ key
The end tower is moving as long the „+“ key is held
- Press and hold the „–“ key
The central tower is moving as long as the „–“ key is held
- Hold the „+“ or „-“ keys until the misaligned spans are properly re-aligned
- Check travel direction when spans start moving. In case of wrong direction release key at once.
Press keys "R" or "F" to activate the tower alignment switches (for manual alignment at tower - concerns alignment
control units with tower alignment switch)
CAUTION!
Selecting the proper running direction ensures that only the outer misaligned towers
start moving when the drive is turned on.
The wrong running direction will cause impermissibly high stress on the trussing.
NOTE!
The towers only move as long as you hold the "+” or "-" key..
NOTE!
The inward towers may start moving for a short time after the start-up
CAUTION!
Continuously check tower movement after the start in order to be able to stop the
system again immediately should the doglegging continue (Release “+” or " -" key).
As soon as the towers are re-aligned (forming a straight line) and the inward towers also start to move, release the
“+” or the “-“ key.
Put the safety circuit switch to “ON”
NOTE !
Operating the BAUER LINESTAR with "SAFETY CIRCUIT SWITCH turned to “OFF" is
only permitted for system alignment.
Test proper moving of the LINESTAR by a short touch of the "Forward“ or „Reverse“ key.
Operation Manual for BAUER LINESTAR 5000
52
20
TECHNICAL DATA
20.1 DIMENSIONS OF BAUER LINESTAR 5000 – 2 WHEEL
20.2 DIMENSIONS OF BAUER LINESTAR 5000 – 4 WHEEL ONE SIDED
Operation Manual for BAUER LINESTAR 5000
53
20.3 DIMENSIONS OF BAUER LINESTAR 5000 – 4 ‚WHEEL DOUBLE SIDED
21
OPTIONS
21.1 LOW PRESSURE SHUT-OFF
The supply pressure on the central tower is monitored by a pressure gauge. If the supply pressure is lower than
the minimum pressure set on the pressure gauge, the shut-off valve closes (option), and the Linestar shuts down.
CAUTION
This will only happen under the condition the “WET-DRY” switch has been set to
“WET”.
If it has been put to “DRY” position the pressure gauge is inoperable..
When turning the switch to “DRY” position the machine runs without irrigating (dry run). This may be necessary
when moving the LINESTAR to a parking position because of natural rainfall.
21.2 ELECTRIC SHUT-OFF VALVE (CENTRAL TOWER)
An electric shut-off valve in the supply line of the central tower is closed automatically, if the LINESTAR shuts down
by malfunction.
21.3 END GUN
To increase the irrigated strip width or the system spraying range inside the swivelling area, an end gun can be
mounted at the end of the LINESTAR overhang. It may spray along the whole irrigation strip or only along parts of
it.
If the end gun is thought to operate in interval mode, an automatic “ON/OFF” control unit must be installed.
Operation Manual for BAUER LINESTAR 5000
54
21.4 BOOSTER PUMP FOR END GUN
In most cases the end gun needs a higher pressure than the other nozzles of the LINESTAR.
An electric booster pump mounted on the end tower generates the necessary operating pressure for the end gun.
The booster pump is connected to the gun on the overhang by a pressure hose..
21.5 AUTOMATIC INTERVAL CONTROL
If the end gun is equipped with a big nozzle for a large spray range, the application rate at the end of the system is
too high. This will be compensated by an automatic interval control which opens and closes automatically a 2”
valve gate and controls the operating time of the end gun.
Operating and break times of the end gun can be set at the TIME/BREAK relay.
21.6 AUTOMATIC „ON/OFF” AND INTERVAL CONTROL
This control unit combines the two above mentioned controls for the end gun and the booster pump..
21.7 TOWER ALIGNMENT SWITCH
This switch is mounted outside on the base plate of the alignment control. It allows the forward or backward move
of the tower without having to open the alignment control. This device facilitates system alignment at first start-up
or after changing the operating site.
21.8 TAIL LIGHT
Mounted on the end tower or on the central tower. This light is shining as long as the LINESTAR is operating.
21.9 END STOP
If it is necessary to stop the system precisely at the field
end, system shut-down takes place at the end tower. A
contact limit switch mounted on the end tower is actuated
by a shut-off frame which is placed at the field end in the
track of the last tower. The machine stops.
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21.10 STOP RAMP
This ramp serves as an emergency stop at the end of the irrigation track. In case every switch-off system is failing,
the end tower will run against the ramp fixed into the soil and the LINESTAR will be stopped mechanically.
Thereafter the motor protection switch of the end tower will shut down the entire system.
22 TOWING OF LINESTAR 2 WHEEL
GENERAL INSTRUCTIONS





System should be towed along an even track, if possible along a cart track (width 7 m).
The track must be even and clear of ruts, grooves and furrows.
If there are ruts in the lane they have to be levelled
Towing of the system inside the field (off road) should be avoided.
If the system has to be towed inside the field, the travelling track must be levelled first and cleared of all
obstacles to avoid any increase of the rolling resistance.
 Max. “towing speed”: 4 km/h
 Min. tire pressure: 1 – 1.1 bar
22.1 TOWING THE LINESTAR FROM CENTRAL TOWER
When towing the central tower a cable bracing from the central tower to the first tower is needed.
22.1.1 Swivelling central tower wheels
Proceed according to item 17.5
Mounting of tow bar
22.1.2 Swivelling tower wheels




Loosen and push back the drive shaft cover at wheel gear .
Loosen driver pin on wheel hub. If wheel gear is provided with shifting lever disengage wheel gear.
Detach gear carrier.
Swivel gear carrier together with wheel. The coupling parts with the rubber packages have to stay at the wheel
gear. If necessary lift wheel carrier with jack or tractors hydraulics.
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Put the drive shaft with the coupling parts on shaft holder which is mounted onto the tower bracing angle.
Fasten wheel gear carrier with connecting brace (turned by 90°).
22.1.3 Mounting the tow cables on 2-wheel central tower




Fasten the clamp on the end pipe of the first tower.
Fasten the clamp on the wheel base of the central tower
Hook up and adjust the cables (the first time)
Mount drawbar (the first time)
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22.2 TOWING THE LINESTAR AT THE END TOWER
22.2.1 Swivelling central tower wheels (proceed according to item 17.5)
22.2.2 Swivelling tower wheels




Loosen and push back the drive shaft cover at wheel gear
Loosen driver pin on wheel hub. If wheel gear is provided with shifting lever disengage wheel gear.
Detach gear carrier.
Swivel gear carrier together with wheel. The coupling parts with the rubber packages have to stay at the wheel
gear. If necessary lift wheel carrier with jack or tractors hydraulics.
Fasten the wheel gear carrier with steering brace “A” (turned by 90°)
Mount steering device “B” on all towers except for end tower (overhang).
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22.2.3 Bracing the end tower


The end tower is braced to the span (on the overhang side) with 2 stabilizing cables.
A drawbar is attached on the wheel carrier.
stabilizing cable
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steering unit
stabilizing cable
59
22.3 TOWING THE LINESTAR AT A FREESTANDING SPAN
22.3.1 Swivelling central tower wheels (according to item 17.5)
22.3.2 Swivelling tower wheels




Loosen and push back the drive shaft cover at wheel gear
Loosen driver pin on wheel hub. If wheel gear is provided with shifting lever disengage wheel gear.
Detach gear carrier.
Swivel gear carrier together with wheel. The coupling parts with the rubber packages have to stay at the wheel
gear. If necessary lift wheel carrier with jack or tractors hydraulics.
Fasten the wheel gear carrier with steering brace “A” (turned by 90°)
Mount steering device “B” on all towers except for end tower (overhang).
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22.3.3 Bracing the end tower and the central tower




The end tower is braced to the span (on the overhang side) with 2 stabilizing cables.
A drawbar is attached to the wheel base.
The central tower is braced to the span with two stabilizing cables
A drawbar is attached to the central tower
stabilizin
g cable
steering
unit
steering
unit
Operation Manual for BAUER LINESTAR 5000
steering
unit
steering
unit
stabilizing
cable
61
23 ELECTRICAL WIRING DIAGRAMS
23.1
Linear control center with Pro Modul
23.1.1
23.1.2
23.1.3
23.1.4
23.1.5
Linear control center with Pro Modul – infeed
Linear control center with Pro Modul – control
Linear control center with Pro Modul – wiring diagram
Linear control center with Pro Modul – wiring diagram
Linear control center with Pro Modul – wiring diagram
23.2
LINESTAR control panel Linear control
23.2.1
23.2.2
Wiring diagram linear control – furrow control
Wiring diagram linear control – cable control
23.3
LINESTAR
23.3.1
23.3.2
23.3.3
23.3.4
standard
with tower alignment switch
End control standard
End control with tower alignment switch
23.4
Booster pump for end gun
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23.1 Linear control center Pro Modul
23.1.1 Linear control center with Pro Modul – Infeed
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23.1.2 Linear control center with Pro Modul – Control
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23.1.3 Linear control center with Pro Modul – Wiring diagram
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23.1.4 Linear control center with Pro Modul – Wiring diagram
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23.1.5 LINEAR Control panel with Pro Modul – Wiring diagram
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67
23.2 LINESTAR control panel Linear control
23.2.1 Wiring diagram linear control – furrow control
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23.2.2 Wiring diagram linear control – cable control
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23.3 LINESTAR Alignment control
23.3.1 Standard alignment control
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23.3.2 Alignment control with tower alignment switch
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71
23.3.3 End control standard
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72
23.3.4 End control with tower alignment switch
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23.4 Booster pump for end guns
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74
24 SERVICE – EVIDENCE
Accomplished service
Yes
No
Date
Operating hours
Confirmed by
Yes
No
Date
Operating hours
Confirmed by
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Oil change
Annual maintenance
Accomplished service
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Oil change
Annual maintenance
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Accomplished service
Yes
No
Date
Operating hours
Confirmed by
Yes
No
Date
Operating hours
Confirmed by
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Oil change
Annual maintenance
Accomplished service
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Oil change
Annual Maintenance
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Accomplished service
Yes
No
Date
Operating hours
Confirmed by
Yes
No
Date
Operating hours
Confirmed by
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Oil change
Annual maintenance
Accomplished service
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Oil change
Annual maintenance
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Accomplished service
Yes
No
Date
Operating hours
Confirmed by
Yes
No
Date
Operating hours
Confirmed by
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Oil change
Annual maintenance
Accomplished service
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Intermediate maintenance
Oil change
Annual maintenance
Operation Manual for BAUER LINESTAR 5000
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25
CONFORMITY CERTIFICATE
EC Declaration of Conformity
according to EC Directive 2006/42/EG
The manufacturer
Röhren- und Pumpenwerk BAUER Gesellschaft m.b.H.
Kowaldstraße 2, 8570 Voitsberg, Austria
Tel: +43 3142 200-0; Fax: +43 3142 200-320/-340
herewith confirms that the machine mentioned below
Designation of machine
Machine type / basic units
BAUER LINESTAR 5000
LINESTAR 5000 - 168 EL
corresponds analogously to the requirements of the Machinery Directive 2006/42/EG.
In case of modification of the machine not accorded with BAUER GmbH, this declaration will cease to be valid.
The following standards as amended have been applied analogously:
DIN EN ISO 12100-1
DIN EN ISO 12100-2
DIN EN 60204-1
EN ISO 14121-1
Safety of machinery - Basic concepts, general principles for design
Part 1: Basic terminology, methodology
Safety of machinery - Basic concepts, general principles for design
Part 2: Technical principles
Safety of machinery - Electrical equipment of machines
Part 1: General requirements
Safety of machinery - Risk assessment
Part 1: Principles
ÖNORM EN ISO 13857 Safety of machinery - Safety distances to prevent hazard zones being
reached by upper and lower limbs
Standards related to products
DIN EN 909
Agricultural and forestry machinery - Centre pivot and moving lateral
types irrigation machines - Safety
Person in charge of documentation:
Thomas Theissl, Kowaldstraße 2, 8570 Voitsberg, Austria,
Technical Designer in Charge
Commercial Manager
Voitsberg, 26.01.2011
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