Spirit Pro

Spirit Pro
Technical Manual
M/N: 201
Version: 1.0
Revision: 1
Date: February 2016
GAVISH CONTROL SYSTEMS LTD.
Kibbutz Naan 7682900 Israel.

Tel/ Fax:: 972-8-9372036
E-mail: info@gavishcontrol.com
Website: http://www.gavishcontrol.com
Spirit Pro Technical Manual

Introduction
Copyright Notice
This publication contains proprietary information belonging to Gavish control systems LTD.,
a Jain irrigation company. This information is supplied only to assist explicitly and properly
authorized users of Gavish control systems LTD.
No part of this document may be used for any other purpose, disclosed to any person or
firm, or reproduced by any means, electronic and mechanical, without the express prior
written permission of Gavish control systems LTD.
The text and graphics are for illustration and reference only. The specifications on which
they are based are subject to change without notice.
No part of this publication is part of any contract or warranty unless specifically
incorporated by reference into such contract or warranty.
The information in this publication is only descriptive in nature, and is not a binding offer for
the sale of the product described herein.
Information in this publication is subject to change without notice. Corporate and individual
names and data used in examples herein are fictitious unless otherwise noted.
Gavish control systems LTD reserves the right to alter the equipment specifications and
descriptions in this publication without prior notice.
© 2015 Gavish control systems LTD., a Jain irrigation company. All rights reserved.
Spirit Pro Technical Manual II

Introduction
Contents
Copyright Notice .........................................................................................................................II
Introduction ................................................................................................................................1
1.1 About Gavish .............................................................................................................................. 2
1.2 About Spirit Pro Irrigation System ................................................................................................. 2
1.3 Safety Summary .......................................................................................................................... 2
1.4 About this Manual ........................................................................................................................ 3
1.5 Applicable Documents ................................................................................................................. 4
Block Diagram Description .........................................................................................................5

2.1 General Block Diagram ................................................................................................................ 6
2.2 Irrigation System Logic ................................................................................................................ 7
2.3 Controller Front Panel .................................................................................................................. 8
Unpacking and Placement .......................................................................................................10

3.1 General..................................................................................................................................... 11
3.2 Unpacking ................................................................................................................................. 12
3.3 Basic On-Site Requirements ...................................................................................................... 13
Fertigation House Setup ..........................................................................................................14

4.1 General..................................................................................................................................... 15
4.2 Tools ........................................................................................................................................ 15
4.3 Building the Fertigation House .................................................................................................... 15
4.3.1 General ........................................................................................................................... 15
4.3.2 Preparing the house and the floor ..................................................................................... 16
4.3.3 Planning the hydraulic system and setup ........................................................................... 16
4.3.4 Leveling the fertigation machine ........................................................................................ 17
4.4 The Electrical Components ........................................................................................................ 17
4.4.1 The controller enclosure ................................................................................................... 18
4.4.2 The electric cabinet .......................................................................................................... 19
4.4.3 Mounting and connecting the controller ............................................................................. 20
4.4.4 Planning the electric power supply system and setup ......................................................... 20
4.4.5 First start of the pump....................................................................................................... 20
4.4.6 Starting the pump and water flow via the line valves and the field valves.............................. 20
4.4.7 Manual filter flush ............................................................................................................. 20
4.4.8 Testing water meter readout ............................................................................................. 21
4.5 Setting Up the Fertigation Machine ............................................................................................. 21
4.5.1 General ........................................................................................................................... 21
4.5.2 Connecting the water inlet and outlet of the fertigation machine .......................................... 21
4.5.3 Loading fertilizers into the fertilizer tank ............................................................................. 21
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4.5.4 Connecting the electric cables of the water meter to the connection strip on the controller and
electronic cards. ........................................................................................................................ 21
4.5.5 Testing the pressostat ...................................................................................................... 21
4.5.6 Testing pressure for AUTOMATIC position ........................................................................ 22
4.5.7 Connecting testing points for EC/pH .................................................................................. 22
4.5.8 Adjusting EC/pH measuring cell ........................................................................................ 22
4.6 Installing the Dissolver Tank ....................................................................................................... 22
4.6.1 General Description ......................................................................................................... 22
4.6.2 Placing the fertilizer tanks ................................................................................................. 24
4.6.3 Installing the blower and air extruders and tests ................................................................. 24
4.6.4 Connecting the dissolver to the fertilization machine ........................................................... 25
4.6.5 Operating the dissolver ..................................................................................................... 25
4.6.6 Agitator manifold .............................................................................................................. 25
Hardware Description...............................................................................................................28
5.1 General..................................................................................................................................... 29
5.2 Irrigation Machine Overview ....................................................................................................... 30
5.2.1 Front view ........................................................................................................................ 30
5.2.2 Rear view ........................................................................................................................ 31
5.3 Detailed Hardware Overview - Inline ........................................................................................... 32
5.4 Detailed Hardware Overview - Bypass ........................................................................................ 33
5.5 Controller Description ................................................................................................................ 36
5.5.1 CPU card description ....................................................................................................... 36
5.5.2 Display card description .................................................................................................... 37
5.5.3 LED card description ........................................................................................................ 37
5.6 Electronic Cabinet Description .................................................................................................... 38
5.7 Typical Terminal Strip Description ............................................................................................... 42
5.8 I/O Card Description .................................................................................................................. 44
5.9 Output Extension Card Description ............................................................................................. 48
5.10 Input Extension Card Description ................................................................................................ 50
5.11 Cards Interconnection Schema ................................................................................................... 51
5.12 Wiring Considerations ................................................................................................................ 54
5.13 RTU Functional Description ........................................................................................................ 55
5.14 Gavish-85 Adapter Description ................................................................................................... 55
5.14.1 General ........................................................................................................................... 55
5.14.2 Hardware description ....................................................................................................... 55
5.15 SMS Transmitter Description ...................................................................................................... 56
5.16 GPRS General Description ......................................................................................................... 56
Electronic Installation Procedures ............................................................................................57

6.1 General..................................................................................................................................... 58
6.2 Tools ........................................................................................................................................ 58
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Introduction
6.3 Main Power Inlet Installation and Power Supply Wiring ................................................................ 58
6.4 Connecting the Controller ........................................................................................................... 59
6.5 I/O Card Installation Procedure ................................................................................................... 67
6.6 Output Extension Card Installation Procedures ............................................................................ 67
6.7 Input Extension Card Installation Procedures .............................................................................. 68
6.8 Gavish-85 Installation ................................................................................................................ 68
6.8.1 General ........................................................................................................................... 68
6.8.2 Hardware description ....................................................................................................... 69
6.8.3 Wiring instructions ............................................................................................................ 69
6.9 Meteorological Station Installation ............................................................................................... 71
6.9.1 Contents .......................................................................................................................... 71
6.9.2 Setup .............................................................................................................................. 71
6.9.3 Ventilated cell .................................................................................................................. 77
6.10 SMS Modem ............................................................................................................................. 79
6.10.1 SMS Modem Installation ................................................................................................... 79
6.11 GPRS Modem ........................................................................................................................... 84
6.11.1 GPRS Modem set up and installation ................................................................................ 84
6.11.2 Enable GPRS service ....................................................................................................... 86
6.11.3 Enable communication between GreenLine (on the PC) to a GPRS modem ........................ 88
6.12 EC/pH Monitoring System Installation and calibration ................................................................... 89
6.12.1 Sampling cell description – new version ............................................................................. 89
6.12.2 Sampling cell description – previous version ...................................................................... 91
6.12.3 Installation procedures ..................................................................................................... 92
6.12.4 EC/pH converter and transmitter description ...................................................................... 94
6.12.5 Connecting EC/pH converter and transmitter ..................................................................... 94
6.12.6 Calibration procedures ..................................................................................................... 96
Hydraulic Installation Procedures ........................................................................................... 100

7.1 General................................................................................................................................... 101
7.2 Plumbing Installation Instructions .............................................................................................. 101
7.3 Tools ...................................................................................................................................... 101
7.4 Pumps Installation ................................................................................................................... 102
7.4.1 Fertilization pump ........................................................................................................... 102
7.4.2 Venturi pump ................................................................................................................. 104
7.5 Pressure and Vacuum Meters Installation ................................................................................. 106
7.5.1 Pressure display ............................................................................................................ 106
7.5.2 Pressure compensation valve ......................................................................................... 106
7.6 Low Pressure Switch Installation .............................................................................................. 108
7.6.1 General description ........................................................................................................ 108
Communication Network Installation and Setup ..................................................................... 111

8.1 General................................................................................................................................... 112
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8.2 Connecting the PC to the Controller .......................................................................................... 112

8.3 Connecting GreenLine View PCs to the Network ....................................................................... 114
8.3.1 Network deployment ....................................................................................................... 114
Post-Installation Preliminary Test ........................................................................................... 116

9.1 General................................................................................................................................... 117
9.2 Testing inputs and outputs ....................................................................................................... 117
9.2.1 I/O cards tests ............................................................................................................... 117
9.2.2 Extension cards test ....................................................................................................... 122
9.3 Testing the CPU card............................................................................................................... 124
9.4 Testing PC inputs .................................................................................................................... 125
9.5 Functional Tests ...................................................................................................................... 125
9.5.1 General ......................................................................................................................... 125
9.5.2 Irrigation system test ...................................................................................................... 125
Software Download and Update ............................................................................................. 127

10.1 General................................................................................................................................... 128
10.2 Receive and install the distribution kit. ....................................................................................... 128
10.3 Activating “ProgPLC” program .................................................................................................. 128
10.4 Send program to the PLC ......................................................................................................... 132
10.5 Troubleshooting for communication failure ................................................................................ 133
10.6 Send program to I/O card ......................................................................................................... 133
Periodic Maintenance Directives ............................................................................................ 137

11.1 General................................................................................................................................... 138
Troubleshooting ..................................................................................................................... 139

12.1 General................................................................................................................................... 140
12.1.1 Alarms Analysis ............................................................................................................. 140
12.1.2 General Symptoms ........................................................................................................ 141
12.2 Inspect your system for leaks ................................................................................................... 142
Parts List and Replacement Policy ......................................................................................... 143

13.1 General................................................................................................................................... 144
Spare parts replacement ........................................................................................................ 146

14.1 General................................................................................................................................... 147
14.2 Warning .................................................................................................................................. 147
14.3 Display card and display replacement ....................................................................................... 147
14.4 CPU Card replacement ............................................................................................................ 147
14.5 LED card replacement ............................................................................................................. 148
14.6 I/O card replacement ............................................................................................................... 149
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Introduction
14.7 Output extension card replacement........................................................................................... 150

14.8 Input extension card replacement ............................................................................................. 151
14.9 Meteorology card replacement ................................................................................................. 152
14.10 Ventilation cell replacement ............................................................................................ 153
14.11 Gavish 85 card replacement ........................................................................................... 154
14.12 Meteorology Station Replacement ................................................................................... 155
14.12.1 Wind speed and direction meter................................................................................. 157
14.12.2 Radiation sensor ....................................................................................................... 158
14.12.3 Rain collector ........................................................................................................... 159
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Introduction
List of Figures
Figure ‎2-1: General System Block Diagram .............................................................................. 6
Figure ‎2-2: Irrigation System Overview ..................................................................................... 7
Figure ‎2-3: Control Panel – Front View ..................................................................................... 8
Figure ‎3-1: Fertigation Machine with Plastic Cover ...................................................................11
Figure ‎3-2: Fertigation Machine - Uncovered ...........................................................................12
Figure ‎4-1: Typical Fertigation House Layout ...........................................................................16
Figure ‎4-2: Overview of the Hydraulic and Fertigation System –Bypass kit..................................17
Figure ‎4-3: Controller in Plastic Enclosure – Front View and Internal View ..................................18
Figure ‎4-4: Controller in Metal Enclosure – Front View and Internal View....................................19
Figure ‎4-5: Electronic Cabinet Front ........................................................................................19
Figure ‎4-6: Manual Flush .......................................................................................................21
Figure ‎4-7: Dissolver Tank with Fertilizer Tanks – Cross Section ...............................................22
Figure ‎4-8: Dissolver – General Overview................................................................................23
Figure ‎4-9: Dissolver parts .....................................................................................................23
Figure ‎4-10: Connecting the dissolver to the fertilization machine ..............................................25
Figure ‎4-11: Agitator definitions ..............................................................................................26
Figure ‎4-12: Irrigation menu ...................................................................................................27
Figure ‎4-13: Fert agitator screen .............................................................................................27
Figure ‎5-1: Hardware Structure of the Irrigation System ............................................................29
Figure ‎5-2: Fertigation Machine – Front View ...........................................................................30
Figure ‎5-3: Fertigation Machine – Rear View ...........................................................................31
Figure ‎5-4: FertLine Hardware Overview .................................................................................32
Figure ‎5-5: Bypass machine – Front View................................................................................33
Figure ‎5-6: Bypass machine –Side View..................................................................................34
Figure ‎5-7: Bypass machine Rear View ...................................................................................35
Figure ‎5-8: Controller Enclosure – Internal view .......................................................................36
Figure ‎5-9: CPU card with backup battery................................................................................37
Figure ‎5-10: Display card .......................................................................................................37
Figure ‎5-11: LED card ...........................................................................................................38
Figure ‎5-12: Electronic Cabinet Front ......................................................................................38
Figure ‎5-13: Typical Layout of the Electronic cabinet ................................................................39
Figure ‎5-14: Typical Internal Mechanical Setups ......................................................................40
Figure ‎5-15 Typical Component Layout ...................................................................................40
Figure ‎5-16: Typical Terminal Block Layout - Wall mount ..........................................................42
Figure ‎5-17: Typical Interconnection schema – Wall mount .......................................................42
Figure ‎5-18: Typical Terminal Block Layout – Machine mount ...................................................43
Figure ‎5-19: Typical Interconnection schema - Machine mount ..................................................43
Figure ‎5-20: I/O Card Layout ..................................................................................................44
Figure ‎5-21: Fuse Map of the Main I/O Card ............................................................................47
Figure ‎5-22: Output Extension Card Layout .............................................................................48
Figure ‎5-23: Extension Card Fuse Map ...................................................................................49
Figure ‎5-24: Input Extension Card Layout ................................................................................50
10. Figure ‎5-25: Input Extension card ...................................................................................51
Figure ‎5-26: Cards Interconnection Schema - Overview............................................................51
Figure ‎5-27: Cards Interconnection Schema via Flat cables ......................................................52
Figure ‎5-28: Cards Interconnection Schema via Multi-wire cables ..............................................53
Figure ‎5-29: Gavish-85 Overview............................................................................................55
Figure ‎6-1: Spirit Pro Terminal Strip Wiring Scheme for Plastic case ..........................................60
Figure ‎6-2: Controller in Plastic case – Internal view .................................................................60
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Introduction
Figure ‎6-3: Spirit Pro Terminal Strip Wiring Scheme B ..............................................................61

Figure ‎6-4: Spirit Pro Terminal Wiring Scheme C .....................................................................61
Figure ‎6-5: Main inlet schema ................................................................................................62
Figure ‎6-6: Main I/O Board Connections Scheme A – for metal case ..........................................62
Figure ‎6-7: Main I/O Board Connections Scheme B - metal case ...............................................63
Figure ‎6-8: Main I/O Board Connections Scheme C - metal case ...............................................63
Figure ‎6-9: Main I/O Board Connections Scheme D ..................................................................64
Figure ‎6-10: Main I/O Board Connections Scheme E to Connect Metrological Station - metal case
..................................................................................................................................64
Figure ‎6-11: Output Extension Card Connection Scheme ..........................................................65
Figure ‎6-12: Output extention card case – Internal view ............................................................65
Figure ‎6-13: Digital Input Extension Card Connection Scheme ..................................................66
Figure ‎6-14: Intput extention card case – Internal view..............................................................66
Figure ‎6-15: Output Extension Card Addressing Schema ..........................................................67
Figure ‎6-16: Input Extension Card Addressing Schema ............................................................68
Figure ‎6-17: Gavish-85 Overview............................................................................................69
Figure ‎6-18: Gavish-85 Wiring Schema ...................................................................................69
Figure ‎6-19: Gavish-85 Wiring Diagram ...................................................................................70
Figure ‎6-20: SMS Modem and Gavish-85 in multi-controller set up ............................................71
Figure ‎6-21: Meteorological Station - Assembled......................................................................72
Figure ‎6-22Metrology station - Pole alignment .........................................................................73
Figure ‎6-23: Meteorological Station – Grounding ......................................................................73
Figure ‎6-24: Meteorological Station – Interface Box Mounted ....................................................74
Figure ‎6-25: Meteorological Station – Interface Card ................................................................75
Figure ‎6-26: Meteorological Station – Interconnection schema ..................................................76
Figure ‎6-27: Meteorological Station – Interface Schema ...........................................................76
Figure ‎6-28: Ventilated cell - Enclosure ...................................................................................77
Figure ‎6-29: Ventilated cell – Internal view ...............................................................................78
Figure ‎6-30: Ventilated cell – Internal box and card ..................................................................78
Figure ‎6-31: Ventilated cell – Interconnection schema ..............................................................79
‎6-32: Modem General View ....................................................................................................79
‎6-33 Modem – Front side .......................................................................................................80
‎6-34 Modem – Rear side........................................................................................................80
‎6-35: Mechanical Characteristics of the Modem .......................................................................80
Figure ‎6-36: SIM card - Insert .................................................................................................81
‎6-37: : SMS/GPRS Transmitter External box – top view ............................................................82
Figure ‎6-38: SMS/GPRS Transmitter External box –side view ...................................................83
Figure ‎6-39: GPRS communication schema.............................................................................84
Figure ‎6-40: GPRS Modem Gavish-85 in multi-controller set up.................................................85
Figure ‎6-41: GPRS Modem connected to single controller.........................................................85
Figure ‎6-42: SMS/GPRS enclosure – Internal view ...................................................................86
Figure ‎6-43: Sampling cells mounted ......................................................................................90
Figure ‎6-44: Sampling cell extracted .......................................................................................90
Figure ‎6-45: EC/pH electrodes extracted .................................................................................91
Figure ‎6-46: Sensors Sampling Cell ........................................................................................92
Figure ‎6-47: Sampling Cell Components .................................................................................93
Figure ‎6-48: EC/pH converter and transmitter with digital display ...............................................94
Figure ‎6-49: EC/pH monitor Interconnection schema ................................................................95
‎6-50: CE/pH Monitor Front .....................................................................................................95
Figure ‎6-51: EC/pH Converter and Transmitter ........................................................................96
Figure ‎6-52: EC/pH Calibration buffer......................................................................................97
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Figure ‎6-53: Sampling Cell Open ............................................................................................99

Figure ‎6-54: Sampling Cell Flow Nozzle ..................................................................................99
Figure ‎7-1: Fertilization Pump Components ........................................................................... 102
Figure ‎7-2: Venturi Pump Overview and Cross Section ........................................................... 104
Figure ‎7-3: Venturi Manifold ................................................................................................. 105
Figure ‎7-4: Pressure and Vacuum Gouge .............................................................................. 106
Figure ‎7-5: Pressure Compensation Valve ............................................................................. 107
Figure ‎7-6: Low Pressure Switch - Pressostat ........................................................................ 108
Figure ‎7-7: Low Pressure Switch .......................................................................................... 109
Figure ‎7-8: Pressostat Reset Trips ........................................................................................ 110
Figure ‎8-1: PLC Communication Definitions Window .............................................................. 113
Figure ‎8-2: PLC to PC Interconnection Schema ..................................................................... 113
Figure ‎8-3: Multi-Viewer Deployment .................................................................................... 115
Figure ‎9-1: Inputs/Outputs definitions .................................................................................... 117
Figure ‎9-2: Communication indicators ................................................................................... 118
Figure ‎9-3: Resistance test - Setup ....................................................................................... 120
Figure ‎9-4: Voltage test - Setup ............................................................................................ 121
Figure ‎9-5: Testing voltage at test points ............................................................................... 122
Figure ‎9-6: Analog extension card ........................................................................................ 123
Figure ‎9-7: Digital input card ................................................................................................ 124
Figure ‎9-8: CPU card test .................................................................................................... 124
Figure ‎9-9: Pressure Sustaining Valve .................................................................................. 126
Figure ‎10-1: GeenLine – Top bar .......................................................................................... 128
Figure ‎10-2: Backup, Restore window ................................................................................... 128
Figure ‎10-3L GreenLine\Applic window ................................................................................. 129
Figure ‎10-4: ProgPlc window ................................................................................................ 129
Figure ‎10-5: PC comm setup window .................................................................................... 130
Figure ‎10-6: Connecting RS-232 cables ................................................................................ 130
Figure ‎10-7: Connecting Gavish 085 ..................................................................................... 131
Figure ‎10-8: PLC menu ....................................................................................................... 132
Figure ‎10-9: DP Male connector ........................................................................................... 133
Figure ‎10-10: ProgPlc window .............................................................................................. 134
Figure ‎10-11: The Spy window ............................................................................................. 134
Figure ‎10-12: Connect coms in PLC window .......................................................................... 134
Figure ‎10-13: ProgPlc window A ........................................................................................... 135
Figure ‎10-14: ProgPlc window B .......................................................................................... 136
Figure ‎10-15: Connect coms on PLC window ......................................................................... 136
Figure ‎13-1: Fertilization Pump Components ......................................................................... 144
Figure ‎14-1: Display and display card disassemble................................................................. 147
Figure ‎14-2: CPU card disassembly ...................................................................................... 148
Figure ‎14-3: LED card disassembly ...................................................................................... 149
Figure ‎14-4: I/O Card disassembly ........................................................................................ 150
Figure ‎14-5: Output extension card disassembly .................................................................... 151
Figure ‎14-6 Input extension card disassembly........................................................................ 152
Figure ‎14-7: Meteorology card disassembly ........................................................................... 153
Figure ‎14-8: Ventilation cell – external box ............................................................................ 153
Figure ‎14-9: Ventilation cell card disassembly ........................................................................ 154
Figure ‎14-10: Gavish 85 Card replacement............................................................................ 155
Figure ‎14-11: Meteorology Station - Assembled ..................................................................... 156
Figure ‎14-12: Meteorology Station with lightening protector ..................................................... 157
Figure ‎14-13: Anemometer - Disassembled ........................................................................... 158
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Figure ‎14-14: Radiation sensor ............................................................................................. 158

Figure ‎14-15: Rain collector – Side view ................................................................................ 159
Figure ‎14-16: Rain Collector base on pate ............................................................................. 160
Figure ‎14-17: Rain Collector base with callouts ...................................................................... 161
Spirit Pro Technical Manual IX

1
Introduction

Introduction
1.1 About Gavish

A GAVISH control system, a Jain irrigation company, is a leading manufacturer of
control systems for the agricultural market. We produce software and hardware to
operate, monitor and control many functions within greenhouses, dairy farms and
fish farms.
GAVISH's three major product lines are: GreenLine, DairyLine and AquaLine.
Since 1980, GAVISH has developed and supplied computerized electronic systems to
the agricultural industry throughout the world. GAVISH's products are widely used in
many countries, including Australia, Japan, China, France, Ethiopia, Kenya, Mexico
and other countries.
GAVISH's control systems enhance efficiency and productivity of the farm.
Our products use advanced technology controlled by a user-friendly Human Machine
Interface (HMI) developed by GAVISH control systems. GAVISH's control systems are
open systems that you can easily install, integrate, operate and update.
Computerized fertigation and irrigation systems of GAVISH control systems improve
crop yields and maximize your revenue.
1.2 About Spirit Pro Irrigation System

The Spirit Pro computer controlled fertilizer injection machine combines up-to-date
computer technology with advanced software and instrumentation. This
combination allows you to set up multiple fertilizer programs for various crops.
You can irrigate according to a time schedule, solar radiation and moisture levels.
1.3 Safety Summary

The following list the minimal precautions to take when installing and operating the
system:
 Read this manual carefully before installation.
 Failure to follow appropriate safety guidelines can result in severe personal
injury or property damage.
 Always exercise proper caution when working with electrical and mechanical
equipment.
 Disconnect the main inlet power supply before handling any electric
equipment.
 Disconnect the power supply before handling the water pump.
 Do not connect the system to outlets above the permissible levels of voltage.
 Connect the system to a valid grounding terminal and verify that the
grounding is less than 4 Ω.
 Follow all local regulations for storage and handling of chemicals.
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Introduction
Acid solutions:
 Do not concentrate the acid solution in the acid solution tank above 12% by
volume.
 Higher concentrations may damage the equipment, and is out of warranty.
 Use all necessary safety equipment, including rubber gloves, protecting
glasses and gas mask, before performing any maintenance on the fertilizer
pipes and fertilizer pumps.
 Close the valves on the fertilizer tanks before performing maintenance on the
fertilizer pipes and fertilizer pumps.
 Release all pressure at the piping before performing maintenance on the
water pipes.
 Use protective equipment, gloves and goggles when handling fertilizers, acids
and other chemicals.
 A technician or engineer trained in the local and national electrical standards
should perform all tasks associated with the electrical wiring of the Spirit-Pro.
1.4 About this Manual

This manual describes the Spirit Pro fertigation and irrigation controller and provides
instructions for setup and installation.
The instructions and information in this volume are arranged as follows:
Section 1 Describes the Spirit Pro irrigation system and introduces

Introduction the reader to the manual.
Section 2 Describes the basic structure and functions of the Spirit

Block Diagram Description Pro system.
Section 3 Describes how to safely unpack the system and the site
Unpacking and Placement requirements for proper installation.
Section 4 Describes how to safely set up a typical fertigation house

Fertigation House Setup and install the Spirit Pro system in it.
Section 5 Describes the Spirit Pro system and provides illustrations

Hardware Description of its major components.
Section 8 Describes how to connect PCs to the Spirit Pro PLC

Network Installation and controller.
Setup
Section 6 Describes installation procedures of the electronic

Electronic Installation equipment and devices in the system.
Procedures

Introduction
Section 7 Describes the installation procedures of the hydraulic

Hydraulic Installation parts of the system.
Procedures
Section 8 Describes how to connect PCs to the Spirit Pro PLC

Network Installation and controller.
Setup
Section 9 Describes the tests that verify system functionality after

Post-Installation Test installation.
Section 10 Describes downloading the PLC controller program to site

Software Download and requirements and updating the PLC software.
Version Update
Section 11 Describes the periodic maintenance cycle.

Periodic Maintenance
Directives
Section 12 Lists troubleshooting instructions based on symptoms and

Troubleshooting error messages.
Section 13 Lists the replaceable spare parts and replacement policy

Parts list and replacement guidelines.
policy
Section 14 Describes the replacement procedures of field replaceable

Spare parts replacement parts.
1.5 Applicable Documents

Operational instructions for PLC controller and GreenLine PC application are
described in the relevant user guides.
 Spirit Pro PLC User Guide
 Spirit Pro PC User Guide

Block Diagram Description
2

2.1 General Block Diagram

The following block diagram illustrates the basic set up of the system that contains:
 Water source
 Fertilization system
 Irrigation system
 Control system
 Interface (HMI)
The fertilization system mixes and applies fertilizers to be injected in the irrigation
system.
The irrigation system applies water to the land or soil to assist growing of agricultural
crops.
The control and monitoring system monitors and regulates variables, such as
amounts of water used, mix of fertilizers and micronutrients, and fertigation
parameters.
The HMI interface handles the human–machine interaction between the operator
and the control systems.
Figure ‎2-1: General System Block Diagram

2.2 Irrigation System Logic

A multi-channel fertigation machine improves the efficiency and accuracy of water-
nutrient mixing. The hardware includes a programmable logic controller (PLC), a
panel interface system and multi-channel sensors.
A sectional forecast control algorithm based on the nutrient dilution model controls
the fertigation machine.
The irrigation program is based on one or more of the following variables:
 Time and duration of watering
 Quantity of irrigation water
 Fertilization program
 Weather conditions
 Soil type and water potential
Below, a generic system overview illustrates the water flow and the mixing
procedure of fertilizers. The quality of fertilized water is continuously monitored by
EC and pH sensors.
The irrigation line valves are controlled by the system logic. System sensors monitor
multiple variables, including the soil and weather conditions and more.
The PLC controls all these procedures, according to the selected fertigation program.
The user interacts with the system via the control panel keyboard and screen.
Figure ‎2-2: Irrigation System Overview

2.3 Controller Front Panel

The control panel is illustrated below. The callouts in the illustration refer to the
sequence numbers in the table below.
Figure ‎2-3: Control Panel – Front View
# Description Function Notes

1 Program screen Displays the main menu icons, and the
status of the system and any alarm.
2 Page Up and Scroll report screen pages up and down.
Page Down
arrows
3 Back Move to previous screen.
4 Navigation key Navigation assistance moves the cursor

within the page.
5 OK Confirm command (enter).
6 COM 2 port Communication between controllers within Tx LED indicates data

indicator the network. transmission, Rx LED
indicates data reception.
7 COM 1 port Communication between controller and Tx LED indicates data
indicator external equipment. transmission, Rx LED
indicates data reception.


8 RUN Green LED indicator. Lit when the system is
operational.
9 Power Green LED indicator. Lit when the system is
powered on.
10 Function keys The assignment of the 4 function keys Function key assignment
change from screen to screen. is displayed on top of the
screen.
11 Numeric Used to enter numeric values on the CLR button clears the last
keyboard screen. entry.

Unpacking and Placement
3

3.1 General
The fertigation machine is packed and shipped in a seaworthy wooden box. Open
the box, lift the plastic cover and extract the machine as illustrated below.
Figure ‎3-1: Fertigation Machine with Plastic Cover

Figure ‎3-2: Fertigation Machine - Uncovered
3.2 Unpacking
During the unpacking procedure check the contents of the box against the packing
list. In case of damaged or missing parts, contact your local distributor.

3.3 Basic On-Site Requirements
Water supply requirements

Arrange water flow and pressure according to system requirements at site. Use fresh water
intake suitable for drip irrigation.
Power supply requirements
Possible main inlets:
 24 VAC 50/60 Hz 1 phase
 115 VAC 50/60 Hz 3 phase
 220 VAC 50/60 Hz 3 phase
 220 VAC 50/60 Hz 1 phase
 400 – 460 VAC 50/60 Hz 3 phase

Fertigation House Setup
4

4.1 General
This section details the procedures to prepare and set up a green house.
4.2 Tools
To build and maintain the fertigation machine the following tolls are required.
Tools for hydraulic parts installation
 Adjustable screw wrench
 Pipe wrench
 Plier wrench
 Big screwdriver
 Small screw diver
Tools for electric parts installation
 1 Multi Volt-meter AC, DC (Avo-Meter type) capable to measure up to:
- 50 VDC
- 600 VAC
- 1 A DC
- 20 k 
 1 Screw-driver Tester
 1 Narrow Screw-driver (2-3 mm )
 1 Wide screw-driver (Philips type)
 1 14” long Adjustable pipe wrench
 1 12” long Adjustable bolts wrench
4.3 Building the Fertigation House
4.3.1 General
Build the fertigation house according to the following layout. The layout below is
given only as a guideline. Customize it according to local conditions.

Figure ‎4-1: Typical Fertigation House Layout
4.3.2 Preparing the house and the floor
The fertigation house should be weatherproof to protect the fertigation machine

from rain and other weather damage. The doors must be wide enough to permit
entry of the fertigation machine and fertilizer sacks. Windows must be large enough
to adequately ventilate the fertigation house.
Prepare a level area for all the equipment. Then, prepare a raised stage for the
fertilizer tanks.
4.3.3 Planning the hydraulic system and setup
The following illustration shows a typical overview of the hydraulic and fertigation
system.

Figure ‎4-2: Overview of the Hydraulic and Fertigation System –Bypass kit
Prepare the water supply in advance. The water pressure should be sufficient to
operate the entire fertigation system, including the pumps, main filter, and water
meter with digital readout for the controller, water valves and pressure
compensation valves.
For By-Pass machines, you must mount 2 manual-ball faucets.
4.3.4 Leveling the fertigation machine
Level the machine using the leveling adjustment screws mounted on the base of the
machine.
4.4 The Electrical Components

The controller and the electric cabinet are the main electrical components of the
system.

4.4.1 The controller enclosure
There are 2 enclosure types made from metal and plastic. Controller mounted in the
metal cabinet can be expended to 16 outputs and 16 inputs. In this model the I/O
cards are installed inside the enclosure. Controller mounted in the plastic cabinet
can be expended to 64 outputs and 24 inputs. Illustrations for both types are given
below.
The inputs and outputs can be extended via extension cards detailed in section 6.
Figure ‎4-3: Controller in Plastic Enclosure – Front View and Internal View
To access the interior of the controller mounted in a plastic enclosure turn the 2
thumbscrew on the front panel clockwise and open the door.
The plastic cabinet capacity is planned for 64 outputs and 24 inputs.

Figure ‎4-4: Controller in Metal Enclosure – Front View and Internal View
To access the interior of the controller mounted in a metal enclosure unscrew 4

fastening screws on the front panel and lift the front panel with care to open the
door.
The metal cabinet capacity is planned for 16 outputs and 16 inputs.
4.4.2 The electric cabinet

The electric cabinet houses all the I/O cards and wiring required to interface various
system components with the controller. The front of the cabinet serves as the door
as well a front panel. The front panel elements may vary between controller types.
The panel components are given in the following illustration.
Figure ‎4-5: Electronic Cabinet Front

The front panel elements are listed below and the callouts in the illustration refer to
the sequence numbers in the table.

1 Green LED Lights up when the water pump is active.
2 Red LED Lights up when the pump stops.
3 Water pump Sets the mode of operation of the pump:

rotary switch Manual, 0, Automatic.
4 Main rotary On-Off switch of the box.
switch
The interior of the electric cabinet is given in figure 5-12.
4.4.3 Mounting and connecting the controller
There are two types of controller enclosure, metal cabinet and plastic cabinet.
The rear of the metal cabinet enclosure holds 4 holes to assists wall mounting of the
controller.
The plastic cabinet is shipped with 4 wall mounting fixes for wall mounting.
Cable connection scheme is provided in section 6.
4.4.4 Planning the electric power supply system and setup
The power supply must be planed ahead according to the system requirements at
site.
4.4.5 First start of the pump
To activate the pump, turn on the main rotary switch on the electric cabinet and turn
the water pump rotary switch to the required position. Verify that the pump turns in
the right direction marked by the arrow on the pump. Otherwise check the electrical
installation
4.4.6 Starting the pump and water flow via the line valves and the
field valves
Following the first set up start the pump and the water flow manually.
4.4.7 Manual filter flush
The manual flush of the filters is performed with operating the pump.
The water flow during the manual flush procedure is illustrated below.

Figure ‎4-6: Manual Flush
4.4.8 Testing water meter readout
Check the water flow via the open valves. Check water meter readout.
4.5 Setting Up the Fertigation Machine

4.5.1 General
The main steps of the machine setup are listed below.
4.5.2 Connecting the water inlet and outlet of the fertigation machine
The water inlet and outlet are marked by arrows on the machine.
4.5.3 Loading fertilizers into the fertilizer tank
If your fertigation machine is connected to a dissolver tank, load the fertilizer into
the dissolver tank. Otherwise, add the liquid fertilizer directly to the fertilizer tanks.
4.5.4 Connecting the electric cables of the water meter to the

connection strip on the controller and electronic cards.
The terminal strips are illustrated in section 6 and cards with interconnection
schema.
4.5.5 Testing the pressostat

For pressostat adjustment see section 7.6 Low Pressure Switch Installation.

4.5.6 Testing pressure for AUTOMATIC position
Start the fertigation machine pump and verify that the pressure on the gauge is
above 2.5 bar.
4.5.7 Connecting testing points for EC/pH
See section 6.12 EC/pH Monitoring System Installation and calibration
4.5.8 Adjusting EC/pH measuring cell
See section 6.12 EC/pH converter and transmitter description
4.6 Installing the Dissolver Tank

4.6.1 General Description
The fertilizer dissolver tank helps the grower maintain homogeneous fertilizer
solutions by dissolving the fertilizers before they are pumped into the fertilizer tanks.
An illustration of the cross section of the dissolver tank with fertilizer tanks is below.
Figure ‎4-7: Dissolver Tank with Fertilizer Tanks – Cross Section
The dissolver tank is illustrated below in various aspects.

Figure ‎4-8: Dissolver – General Overview
The following illustration shows the main parts of the dissolver tank. The callout
numbers in the illustration refer to their sequence numbers in the table.
Figure ‎4-9: Dissolver parts


1 Blower Forces air into the dissolver tank.
2 On/Off switch 20 minute timer for small (1-phase) blowers

for the blower only. For 3-phase blowers, no timer required.
(with timer)
3 On/Off switch Start/Stop switch of the magnetic pump.
for the magnetic
pump
4 Pipe Water input pipe.
5 Output pipes Output to fertilizer tanks.
6 Pump Magnetic pump forces dissolved fertilizers into

fertilizer tanks.
7 Filter Filters input water.
8 Valve NC valve on the tank outlet to prevent

fertilizer flow when the machine is not
operational.
9 Filter Filters dissolved fertilizer from the fertilizer
tanks to the machine.
Install the dissolver per the following steps:

1. Install Dissolver tank on flat floor and Air Blower on wall next to the tank
2. Connect the PVC internal manifold to air blower, use 1” flexible hose
3. Install Magnetic pump at tank outlet
4. Install PVC division manifold on closed wall
5. Assemble fertilizer outlet from fertilizer tank to fertilizer pipes
6. Connect fertilizer pipes to fertilizer machine, using ½” flexible hoses
4.6.2 Placing the fertilizer tanks
Place the fertilizer tanks on a stage higher than the floor where you placed the
fertigation machine. The tanks should be horizontally level.
4.6.3 Installing the blower and air extruders and tests
The blower has to be installed above the water level of the tank. Test the blower
before operating the dissolver.

4.6.4 Connecting the dissolver to the fertilization machine
Connect the fertilization outlet of the dissolver tank to the fertilizer inlet of the
fertilization machine via flexible tubing as illustrated below.
Figure ‎4-10: Connecting the dissolver to the fertilization machine
4.6.5 Operating the dissolver
The following details the operational procedures of the dissolver.

1. Fill tank with water according to required fertilization solution
2. Pour fertilizer powder to tank through the strainer
3. Activate manually the Air blower until powder completely dissolved (few minutes).
Air blower pre-regulate to maximum 15 minutes
4. Open 1.5” valve at tank outlet and open 1” valve on division manifold to first
fertilizer tank
5. Activate Magnetic pump manually, until dissolving tank is completely empty
6. Start same procedure for next fertilizer powder
To maintain the dissolver perform the following steps:
1. After finish dissolving and delivery of all fertilizers – flush the tank by fresh water.
2. Flush Magnetic pump by fresh water, deliver it outside to drain through manual
valve
4.6.6 Agitator manifold
The agitator is used to achieve homogeneous fertilizers solution. This method is

mostly applicable for low temperature environments.

This mechanism drives to air from the blower to the agitator manifold mounted at
the bottom of the dissolver and fertigation fertilizer tanks.
This mechanism can be operated manually (locally) or remotely from the PC or the
controller. To activate this option set the operation box to AUTO.
Activating the agitator from the PC.
Access the Agitator definitions screen (given below) via the Head menu.
Figure ‎4-11: Agitator definitions
Mode of operation: OFF-man / Auto / ON-man

Daily:
Daily activation time: Activate each day at defined time.
For (sec): Activate for defined seconds.
Activate before irrigation, for (sec): Activate before each irrigation, for defined
seconds.
Cycle structure during irrigation:
ON time (sec): On duration, seconds.
OFF time (min): OFF duration, minutes.
Status: Agitator work status.
Last work time: Time of last agitator activation.
Activating the agitator from the controller
Access the Fert agitation screen (given below) from the Irrigation menu.

Figure ‎4-12: Irrigation menu
Figure ‎4-13: Fert agitator screen
Irrigation head: select irrigation head number.

Mode of operation: OFF-man / Auto / ON-man
Once a day, at: Activate each day at defined time.
For (sec): Activate for defined seconds.
Activate before irrigation, for (sec): Activate before each irrigation, for defined
seconds.
During irrigation, every (min): Activate during irrigation, every defined minutes
For (sec): For defined seconds.
Status: Agitator work status.
Last work time: Time of last agitator activation.

Hardware Description
5

5.1 General
The PLC controller is the core of the system. The controller includes the main
processor (CPU), program logic and the HMI (Human Machine Interface). The
operator interfaces with the system via the HMI. The PLC controller is shipped in
various versions in metal enclosure or plastic enclose as listed in the price list of
GAVISH.
The PLC interfaces with the various system elements via the I/O cards. The system
elements include line valves, field valves, meters and indicators.
You can operate the PLC directly via the PLC front panel or remotely by a PC program
over an RS-232 link.
You can also integrate the PLC into a network over an RS-485 link.
If you overview the system through PC software, the PC interfaces over an RS-232
link through a converter.
Figure ‎5-1: Hardware Structure of the Irrigation System
The controller can be supplied in various versions as listed in GAVISH pricelist.

5.2 Irrigation Machine Overview

5.2.1 Front view
The illustration below shows the front view of a fertigation machine when the
controller is installed in a metal enclosure. The callouts in the illustration refer to the
sequence numbers in the table below.
Figure ‎5-2: Fertigation Machine – Front View

1 PLC panel Contains the controller and The PLC front panel
interface panel. further detailed in
section ‎2.3.
2 Electric cabinet Contains the I/O cards of the
system.
3 EC/pH monitor Contains the EC/pH monitor.
and transmitter

5.2.2 Rear view
The illustration below shows the rear view of a fertigation machine.
Figure ‎5-3: Fertigation Machine – Rear View

5.3 Detailed Hardware Overview - Inline

The illustration below shows the main parts of the FertLine fertigation and irrigation
control system. The callouts in the illustration refer to the sequence numbers in the
following table.
Figure ‎5-4: FertLine Hardware Overview
# Description # Description
1 Electrical cabinet 13 Fertilizer visual flow meter
2 Controller (PLC) 14 Fertilizer manual flow regulator
3 EC/pH Monitor and transmitter 15 Fertilizer electric solenoid valve
4 Control filter/Disk filter 16 Fertilizer inlet
5 Water pump ("booster") 17 Negative water pressure (vacuum) gauge
6 Main water inlet 18 Main outlet pressure gauge
7 Main water outlet 19 EC/pH measuring cell with low pressure
electrodes
8 Digital water meter 20 EC/pH sampling point
9 Main electricity power switch 21 Water pump pressure protection switch
10 Water pump "WORK" indicator 22 Automatic air release valve
(green)
11 Water pump "OVERLOAD 23 Water Pressure Sustaining Valve (manual or
ALARM" indicator (red) automatic) (PSR)
12 Water pump control selection 24 Leveling adjustment screws
switch
25 Pressostat is set at 2 bars by the vendor. If the
water pressure drops below this level pump
stops

5.4 Detailed Hardware Overview - Bypass

FertiLine components, front view.
Figure ‎5-5: Bypass machine – Front View
Legend:
1. Main power switch.
2. Buster pump running LED indicator, green.
3. Buster pump switch: Auto / Manual. Set it to Auto for normal operation.
4. Alarm LED red – lit when the pump is overloaded or motor overload protection
is initiated.
In Auto the vacuum pump operation is commanded by the controller.

In Manual the vacuum pump starts manually.

FertiLine components, side view.
Figure ‎5-6: Bypass machine –Side View
Legend:
1. Visual flow meter (1000 L/h)
2. Solenoid valve
3. Fert counter
4. Air eject ball valve
5. Optional water inlet.
6. Water outlet
7. Water outlet
8. Main PLC
9. Two pressure displays
10. Booster pump
11. Sampling cell
12. Pressure compensation valve
13. Water Pressure Sustaining Valve

FertiLine components, rear view.
Figure ‎5-7: Bypass machine Rear View
Legend:
8. Air eject ball valve
9. Another option for water inlet
10. Water outlet
11. Water inlet

5.5 Controller Description

The controller is mounted in an envelope.
The controller includes the HMI display, keyboard, CPU card and the terminal strip.
The front panel of the controller is functionally detailed is section 2.3.
The illustration below shows the interior of the controller.
Figure ‎5-8: Controller Enclosure – Internal view

1 Display card Interface to the display
2 CPU card Controller processor card
3 LED card Interface to the panel LEDs
4 Transformer Transformer main inlet to 24VAC
5 I/O card Main interface card of the controller
6 TB Terminal strip
5.5.1 CPU card description
The illustration below shows the interior of the CPU card with backup batter.
The CPU card is the main processor unit of the system.

Figure ‎5-9: CPU card with backup battery
5.5.2 Display card description

The display card is a graphic display card to drive the front panel display
Figure ‎5-10: Display card
5.5.3 LED card description
The LED card drives the LEDs mounted on the front panel of the Controller.

Figure ‎5-11: LED card
5.6 Electronic Cabinet Description

The electronic cabinet contains the I/O card, the terminal strip and the extension
cards. The electronic cabinet enclosure can be plastic or metal.
Sections ‎5.8 through ‎5.10 below detail these parts.
The front of the box serves as the door and as a front panel. The front panel
elements may vary between controller types. The following is a representative
layout.
Figure ‎5-12: Electronic Cabinet Front
The front panel elements are listed below and the callouts in the illustration refer to
the sequence numbers in the table.

1 Green LED Lights up when the water pump is active.
2 Red LED Lights up when pump stops working (Warning).
3 Water pump Sets the mode of operation of the pump:

rotary switch Manual, 0, Automatic
4 Main rotary On-Off switch of the box.
switch

The interior of the electronic cabinet vary according to the type of the fertigation
machine.
Typical internal mechanical configurations of the electronic cabinet is given below.
Figure ‎5-13: Typical Layout of the Electronic cabinet

Figure ‎5-14: Typical Internal Mechanical Setups
The following illustrations pinpoint the main components mounted in the electronic
cabinet. The components are listed in the following table below and the callout
numbers refer to the sequence numbers in the table.
Figure ‎5-15 Typical Component Layout


1 Transformer 24VAC Supply
2 Circuit breaker Breaks a circuit under non-normal or fault

conditions.
3 Mini-relays 24VAC with LED
4 Terminal strip Connection and termination for peripheral

devices and/or extension cards.
Figure ‎5 7 Typical Component Layout with EC/pH Monitor

1 Power supply 24VAC
2 EC/pH monitor Monitors the EC and pH and transmits data

and transmitter to the controller
3 I/O Card Interface between controller and peripheral
4 Protective Pump overload protection
switch
5 Mini relays Activating commands
6 Circuit breaker Breaks a circuit under normal or fault

conditions.
7 Terminal strip Connection and termination for peripheral

Note: the electronic cabinet has a fan to ventilate the cabinet and prevent
overheating. The fan operates between -20 C to +80 C, and from 0 to 100%
humidity. Under extreme conditions, the fan operates between -50 C to +50 C.
5.7 Typical Terminal Strip Description

The terminal strip connects the I/O card to the extension cards. If the peripheral
devices of the irrigation system are directly connected to I/O card, there is no
terminal strip in the enclosure of the controller.
Figure ‎5-16: Typical Terminal Block Layout - Wall mount
Figure ‎5-17: Typical Interconnection schema – Wall mount

Figure ‎5-18: Typical Terminal Block Layout – Machine mount
Figure ‎5-19: Typical Interconnection schema - Machine mount

5.8 I/O Card Description

The I/O card is the interface between the CPU card and the peripheral devices of the
irrigation system. You can install the I/O card in the controller envelope or in a
separate enclosure as applicable.
The diagrams below are given as guidelines for interconnection. The practical
connections may vary according to the local set up of the system.
The card layout is below. The callouts refer to the components on the card.
Figure ‎5-20: I/O Card Layout

Legend:
1. 24 VAC fuse, 2A, slow blow.
2. Output relay. Maximum of 24 VAC, 8 watt.
3. Battery connection, for memory backup (not used).
4. Common 24 VAC, to supply voltage to outputs 13 to 16. Wire it to the right
side of the output connector. If you do not wire it, outputs 13 to 16 have
“dry contact”.
5. Output connectors. “c” is a common “0”. When the relay is ON, At “~” there
is the 24 VAC.
6. Fuse. Used to protect the output relays. There are 2 output relays for each
fuse.
7. LED. Indicates that the output relay is ON.
8. 24 VAC line. When the relay is ON, 24 VAC is flowing through.
9. Common “0” of the 24 VAC lines.
10. Terminal for wiring to output extension cards.
11. “N” line of Comm port 2.
12. “P” line of Comm port 2.
13. “N” line of Comm port 1.
14. “P” line of Comm port 1.
15. Ground of 24 VAC supply.
16. “~” of 24 VAC supply.
17. “0” of 24 VAC supply.
18. Battery. Used to back up the clock if there is a power outage. Requires a CR
2032 battery.
19. Connector for output extension cards.
20. Connector for digital input extension card.
21. Connector for communication port 1.
22. Connector for communication port 2.
23. Input connector.
24. Main CPU chip (user cannot replace on-site).
25. 24 VAC outputs fuse. 5 A, slow blow.
26. Analog voltage calibration. Factory set only.

27. Terminal for Display-panel strip connector.

28. Jumpers. Set to input type, digital or analog. Two lines set one input. The
input number is printed to the right of the fuse.
The jumper settings:
 Analog: connect the two right pins.
 Digital connect the two left pins.
29. RS-232 communication chip, mounted on Communication port 1.
30. RS-485 communication chip, mounted on Communication port 2.
31. 12 VCD fuse. 1 A, slow blow.
32. Communication status LEDs:
 The two left LEDs are green.
 “ON” indicates that the power supply works.
 “Run” indicates the chip's status.
 The following LEDs are red:
 “RX1” is a sign of communication at communication port 1.
 “TX1” is a sign of transmitting at communication port 1.
 “RX2” is a sign of communication at communication port 2.
 “TX2” is a sign of transmitting at communication port 2.
33. Common 24 VDC bridge.
36. 24 VDC fuse, 1 A, slow blow.
37. Transformer, 24 VAC to 24 VDC and 12 VDC.
38. 0 VDC/Ground
39. + 12 VDC
40. Fuse 24 VDC – 1A
41. Transformer
The fuse map of the main I/O card is given below.

Figure ‎5-21: Fuse Map of the Main I/O Card

5.9 Output Extension Card Description

The output extension cards extend the system's capacity. You can install up to 3
output extension cards in a system.
The card layout is below. The callouts refer to the card details.
Figure ‎5-22: Output Extension Card Layout
Legend:
1. Output relay.
2. Relay fuse, 2 A slow blow.
3. Relay LED.
4. 24 VAC line. When the relay is ON, 24 VAC is flowing through.

5. Common “0” of the 24 VAC lines.

6. 24 VAC power supply connectors.
7. Relay fuse, 6 A slow blow.
8. Receptacle to wire to main Spirit and other extensions.
9. Receptacle for flat cable, output to other extensions.
10. Receptacle for flat cable, input from Spirit or other extensions.
11. Board fuse, 1 A slow blow.
12. I.D. setting switch.
 1:on+2:off = ID1
 1:off+2:on = ID2
 1:on+ 2:on = ID3
 The fuse map of the card is given below.
Figure ‎5-23: Extension Card Fuse Map

5.10 Input Extension Card Description

The input extension cards extend the system capacity. You can add 1 input extension
card.
The card layout is given below. The callouts refer to the card details.
Figure ‎5-24: Input Extension Card Layout
Legend:
1. LED: power supply indication
2. 24 VDC terminal
3. 12 VDC terminal
4. 0 VDC terminal
5. Receptacle for flat cable to connect to the main I/O board
6. “+” VDC input terminal
7. “–” VDC input terminal
8.

9.
10. Figure ‎5-25: Input Extension card
5.11 Cards Interconnection Schema

The following schema shows the connections between the various cards in a fully-
deployed irrigation system.
Figure ‎5-26: Cards Interconnection Schema - Overview
The cards are interconnected via flat cables as illustrated below. I case of fail of the
flat cable the flat cable can be replaced by multi-wire cable 5 X 6005. The length of
the multi-wire cable shall not exit 1.5 meters. If the LEDs (green and/or red)
mounted on the card does not lit can be one of the indications of cable fail.

Figure ‎5-27: Cards Interconnection Schema via Flat cables

Figure ‎5-28: Cards Interconnection Schema via Multi-wire cables

5.12 Wiring Considerations

Follow these wiring guidelines:
 The wiring of the Spirit is designed to be safe and easy.
 A technician or engineer trained in the local and national electrical standards
should perform all the electrical wiring tasks required.
 Input and/or output cables should not run through the same multicore cable
or share the same wire.
 Do not lay input/output cables close to high-voltage power cables.
 Allow for voltage drop and noise interference input/output lines.
 Use only wire that is adequate for the current load.
 Double-check all the wiring before turning on the power supply.
Cabling specifications are listed the table below
Device From To Cable type Cable lengths
Meteorological Card Controller 7 X 0.75 mm 20 meter

station
Ventilated cell Card Controller 7 X 0.75 mm 20 meter
EC/pH monitor Converter Controller 7 X 0.75 mm 5 meter
SMS Modem Controller 7 X 0.75 mm 5 meter

Com1
GPRS Modem Controller 7 X 0.75 mm 5 meter

Com1

5.13 RTU Functional Description

The RTU (Remote Terminal Unit) connects physical devices to a control system by
transmitting messages from the system to the devices.
The RTU transmitter mounted next to the controller transmits control data to the
RTU receivers installed next to the device to be controlled.
You can connect RTUs by landline cables or via wireless radio equipment.
You can use repeaters to extend the effective range of the wireless RTU link.
The RTU devise is detailed further in the RTU manual.
5.14 Gavish-85 Adapter Description

5.14.1 General
The Gavish-85 bidirectional communication converter converts from RS-232 to RS-

485 protocols. It also uses a lightning protector, which is grounded to the electric
supply grounding.
You must install the Gavish-85 at any installation where the PC is connected to the
PLC.
Figure ‎5-29: Gavish-85 Overview
5.14.2 Hardware description
 Housing: metal.
 Communication: RS-232 to RS-485, bidirectional, half-duplex.
 Input power supply: 230 VAC or 115 VAC. Optional voltages: 12 VDC, 24 VDC.
 LED display: power, RX, TX.
TX blinks indicating transmission toward the network
RX blinks indicating transmission toward the connected device
 Lightning protection: protects the PC against lightning by grounding the
lightening to the electric supply grounding.

5.15 SMS Transmitter Description

The SMS transmitter installed next to the controller transmits error messages to
stakeholders over a cellular network. In the Spirit Pro PC application, you can enter
up to five stakeholders to receive SMS messages.
The SMS setup screen is detailed in PC user guide section 4.13.
The installation procedures are detailed in this technical manual, section ‎6.10.
5.16 GPRS General Description

General packet radio service(GPRS) is a packet oriented mobile data service on
cellular communication system's global system for mobile communications(GSM).
GPRS in The Spirit Pro fertigation system enables transfer of data from the Green
Line application over the internet via GPRS transmitter in half-duplex mode.
The installation procedures are detailed in this technical manual, section ‎6.11

Electronic Installation Procedures
6

6.1 General
This section describes installation procedures of the electronic equipment and
devices in the system.
Wire Considerations
The wiring of the Spirit Pro has been designed to be safe and easy. A technician or
engineer trained in the local and national electrical standards should perform all
tasks associated with the electrical wiring of the Spirit.
Input or output cables should not be run through the same multicore cable or share
the same wire.
Do not lay input/output cables near high voltage power cables.
Allow for voltage drop and noise interference with input/output lines used over an
extended distance. Use only wire that is properly sized for the current load.
Double-check all the wiring before turning on the power supply
6.2 Tools
 Multi-tester AVO meter suitable to measure:
50 VDC
600 VAC
1 A DC
20 k 
 Screwdrivers
 Cutters
6.3 Main Power Inlet Installation and Power Supply

Wiring
Main power wiring is subject to local conditions at site.
The connection diagrams provide here serve as guidelines and may change according
to local conditions.

6.4 Connecting the Controller

The lover part of the controller enclosure contains 4 PG type inlets and the
interconnection schema is given in the table below.
Design Output Extension Input Extension Com 1 Com 2
Connector type D-type 15 F D-type 15 M D-type 9M D-type 9M
Protocol RS-232 RS- 485
Connected device Output extension Input extension card SMS modem PC network
card GPRS modem
Notes

Figure ‎6-1: Spirit Pro Terminal Strip Wiring Scheme for Plastic case
Figure ‎6-2: Controller in Plastic case – Internal view

Figure ‎6-3: Spirit Pro Terminal Strip Wiring Scheme B
Figure ‎6-4: Spirit Pro Terminal Wiring Scheme C

Figure ‎6-5: Main inlet schema
Note: This schema can be also adopted for 220VAC / 50Hz power supply
Figure ‎6-6: Main I/O Board Connections Scheme A – for metal case
Note: The 115VAC connection (illustrated here) can be replaced by 220VAC / 50Hz connection.

Figure ‎6-7: Main I/O Board Connections Scheme B - metal case
Figure ‎6-8: Main I/O Board Connections Scheme C - metal case

Figure ‎6-9: Main I/O Board Connections Scheme D
Figure ‎6-10: Main I/O Board Connections Scheme E to Connect Metrological Station - metal case

Figure ‎6-11: Output Extension Card Connection Scheme
Set the DIP switch to define the ID of the card. The addresssing schema is illustarted
in section 6.6. below.
Figure ‎6-12: Output extention card case – Internal view

Figure ‎6-13: Digital Input Extension Card Connection Scheme
Figure ‎6-14: Intput extention card case – Internal view

6.5 I/O Card Installation Procedure

The I/O cards can be installed within the controller cabinet or mounted in the
electric cabined.
If the I/O cards are mounted in the electronic cabinet, use the cables supplied with
the machine to connect the card to the controller.
6.6 Output Extension Card Installation Procedures

The extension cards can be mounted within the electric cabinet or in a separate
enclosure.
The addressing schema of the Output Extension Cards is given below. Dipswitch
settings are illustrated next to each card box. X presents ON.
Figure ‎6-15: Output Extension Card Addressing Schema

6.7 Input Extension Card Installation Procedures

The extension cards can be mounted within the electric cabinet or in a separate
enclosure.
The addressing schema of the of the Input Extension Card cards is given below.
Figure ‎6-16: Input Extension Card Addressing Schema
6.8 Gavish-85 Installation

6.8.1 General
The Gavish-85 bidirectional communication protocol converter converts from RS-232

to RS-485 protocols. It also uses a lightning protector which is grounded to the
electric supply grounding.
You must install the Gavish-85 at any installation where the PC is connected to the
PLC.

Figure ‎6-17: Gavish-85 Overview
6.8.2 Hardware description
 Housing: metal.
 Communication: RS-232 to RS-485, bidirectional, half-duplex.
 Input power supply: 230 VAC or 115 VAC. Optional voltages: 12 VDC, 24 VDC.
 LED display: Power (green – lit when the device is operational,
RX, TX (red – lit when data is sent or received)
TX blinks to indicate transmission to network
RX blinks to indicate transmission to connected device
 Lightning protection: protects the PC against lightening by grounding
lightning to the electric supply grounding.
6.8.3 Wiring instructions

The following diagram illustrates the Gavish-85 wiring connections.
Figure ‎6-18: Gavish-85 Wiring Schema
Rx wire is black and Tx wire is red.

At the PC - connect a “USB-to-Serial” adaptor, (E.g.: Aten UC-232-A) to a USB port.

Pull the RS232 cable (supplied by Gavish), connect it to the Gavish-85, as follows:
Red wire to Tx, Black wire to Rx, Silver wire to the SG terminal.
Pull the RS-485 cable (supplied by Gavish) from the Gavish-85 to Comm2 of the PLC.
On the Gavish-85 - connect Red wire to P, Black wire to N.
At the PLC – connect the cable-end plug into the external socket labeled as
“Comm2”.
Figure ‎6-19: Gavish-85 Wiring Diagram
Connect the Gavish-85:

 To the PLC Com 2 port on the controller and to terminal block 1 on Gavish-85
 To any Com port selected on the PC and to terminal block 2 on Gavish-85
Distances:
 Copper wire is limited to about 1000 meters.
Note
The software installation procedure is in the Spirit Pro PC User Guide, Section 8
In a multi-controller set up the Gavish-85 and the SMS modem should be connected
as illustrated below.

Figure ‎6-20: SMS Modem and Gavish-85 in multi-controller set up
6.9 Meteorological Station Installation

The meteorological station collects data to provide it to the controller.
The meteorological station is interfaced with the controller via an RS-232 interface.
Install the meteorological station on a pole (not supplied) to elevate the station
approximately 2 meters above the top of the green house.
6.9.1 Contents
The meteorological station includes the following devices:

Wind direction meter (anemometer)
Wind speed meter
Solar radiation sensor
Rain gauge (udometer – rain collector)
Humidity sensor
Assembly plane
Ventilated cell
6.9.2 Setup
The meteorological station kit includes all hardware, tools and material required to
set up the station.
An assembled meteorological station is illustrated below.

Figure ‎6-21: Meteorological Station - Assembled
The metrological must be mounted on 2 meters above the roof a the fertigation
house
The lightning protector rod must be installed in such way that its shadow shall never
cover the solar radiation sensor.
After setup of the meteorological station, you must ground it, as illustrated below.
The gauge of the wire must be sufficient to withstand lightening.
Note: The pole must be vertically and horizontally aligned as illustrated below.

Figure ‎6-22Metrology station - Pole alignment
Figure ‎6-23: Meteorological Station – Grounding

Following setup and grounding, interface the meteorological station via a dedicated
interface card installed in a waterproof enclosure. Mount the enclosure on the pole
and connect the devices on the card.
Figure ‎6-24: Meteorological Station – Interface Box Mounted
The interface card is illustrated below.

Figure ‎6-25: Meteorological Station – Interface Card

1 Wind direction and Interface contacts Direction – Analog
speed contacts Sped - Digital
2 Solar radiation Interface contacts Analog
contacts
3 Rain collector contacts Interface contacts Digital
4 Connecting pins Interface pins to I/O card
5 Rain collector Input interface point
6 Rain collector Output interface point
The interconnection scheme of the interface card to the main I/O board is given in
figures (6-4 to 6-10).
Connect the Meteorological Station devices
To connect the Meteorological Station devices to the interface card and to the I/0
card, open the cover of the enclosure, insert the cables via the PG holes of the
enclosure. Insert the cables with the sleeves into the connector holes and press
gently on the cover of the connector to fasten the cable. Verify that the cable color
match the color imprinted on the card.

Figure ‎6-26: Meteorological Station – Interconnection schema
Note: The interconnection cable shall extend 20 meters.
The logical interface schema of the meteorological station with the controller is
given below.
Figure ‎6-27: Meteorological Station – Interface Schema

6.9.3 Ventilated cell
The purpose of the ventilated cell is to measure the temperature and humidity
outside the greenhouse.
The ventilated cell is installed in a separate enclosure and should be mounted in a
covered and protected place and not be exposed to rain.
Range of measurement is 200C to + 800C, humidity 0 to 100%. If the environmental
temperature drops below -200C special arrangement is required prior to shipment.
In such a configuration the range changes from -500C to + 500C.
The ventilated cell enclosure and its interior are illustrated below.
Figure ‎6-28: Ventilated cell - Enclosure

Figure ‎6-29: Ventilated cell – Internal view
Note: The ventilator operates on 24VAC.
Figure ‎6-30: Ventilated cell – Internal box and card

The Ventilated cell enclosure contains a ventilated and an internal compartment to

accommodate temperature and humidity sensors as well the electronic card.
The interconnection schema of the ventilation cell is given below.
Figure ‎6-31: Ventilated cell – Interconnection schema
Note: The interconnection cable shall extend 100 meters.
6.10 SMS Modem

The SMS modem is used to transmit notifications via the cellular network from the
controller to predefined subscribers. Up to 5 subscribers can be defined via the
GreenLine PC application. The SMS modem is operational only when calls are
initiated.
6.10.1 SMS Modem Installation
The SMS transmitter modem is normally already installed in the electronic cabinet,
so installation is not required.
‎6-32: Modem General View
The front and rear site of the modem is given below.

‎6-33 Modem – Front side
‎6-34 Modem – Rear side
Below are the mechanical characteristics of the modem.
‎6-35: Mechanical Characteristics of the Modem
Before using the SMS function, obtain a SIM card from your local cellular radio
provider and insert it into the slide in the modem. To insert the SIM card lift the SIM
card cover on the enclosure an insert the SIM card into the slide as illustrated below.
Pay attention to insert the card in to the slide with care and push it downward with
care.

Figure ‎6-36: SIM card - Insert
If the modem is installed in a separate box, mount the box, then connect the modem
to the controller. If the controller is mounted in metal cabinet connect the modem
directly to Com 1. If the controller is mounted in plastic cabinet connect the modem
via the TB.
The interior of the box is illustrated below. The callouts refer the sequence numbers
in the table below.

‎6-37: : SMS/GPRS Transmitter External box – top view

1 Activating relay Activates the SMS transmitter via software
command from the controller
2 Power supply Supplies 12 VDC
3 Connectors Interfacing connectors to the controller.

For controller in metal enclosure connect
directly to Com 1 on the controller.
For controller mounted in plastic enclosure
connect to Com 1 on the controller via the
terminal block
4 Modem Transmits SMS messages
The side view with cables of the SMS Transmitter External box is given below.

Figure ‎6-38: SMS/GPRS Transmitter External box –side view

1 Communication Communication cable to
cable COM 1
2 Antenna Antenna of the SMS/GPRS Attached to the enclosure via a magnetic
transmitter fastener
3 Control cable Control cable to the On the controller select Technician menu
controller to access Output Status option to define
SMS settings
4 Power cord Main power inlet

6.11 GPRS Modem

The enclosure of the GPRS modem is identical to the SMS modem. The GPRS modem
is continuously operational.
6.11.1 GPRS Modem set up and installation
The GPRS modem communicates with the GreenLine application via TCP/IP and uses
RS-232 to communicate with the controller.
The installation of the GPRS modem is performed as per the following steps.
1. Configuring the GPRS stack within the GreenLine application as described below
to enable communication.
2. Installing the modem next to the controller.
3. Configuring the GPRS modem to communicate with the router at the location of
the PC.
4. Testing the communication
- between the GreenLine application and the modem via TCP
- between the modem and the controller via RS-232
The GPRS communication schema is illustrated below.
Figure ‎6-39: GPRS communication schema
The GPRS device is installed in an external enclose or within the electric cabinet as
applicable.
In a multi-controller set up the GPRS modem and Gavish-85 device and should be
connected with the controllers as illustrated below.

Figure ‎6-40: GPRS Modem Gavish-85 in multi-controller set up
In a single controller setup the GPRS modem can be connected directly to the Com 1
port of the controller as illustrated below.
Figure ‎6-41: GPRS Modem connected to single controller

Figure ‎6-42: SMS/GPRS enclosure – Internal view
To enable operation over the local cellular network the GPRS SIM card must be
obtained from the cellular network operator with a surfing package of 300 MB per
month as a minimum. To insert the GPRS SIM card lift the SIM card cover on the
enclosure an insert the SIM card into the slide.
6.11.2 Enable GPRS service
In order to enable GPRS service on the GreenLine application you have to perform
the following steps.
• At GreenLine – set your authorization level as “Technician”.
• At upper line –activate the “Communication” icon:
If a new window was not opened now – at lower line find and activate the
communication icon:
• The communication status window opens:

• Right-click on the field under the “misc” title:
• In the popup window – click on “gprs” in the popup list.
• The letters GM display in the field under “misc” title:
This marks that this PLC is expected to connect with GreenLine on the PC using GPRS.
TCP server
GreenLine application includes a built-in “TCP server”, to enable communication with
GPRS modem.
Definitions instructions are listed below:
• Stop GreenLine running (use <Alt><X>)
• At “.\Applic” folder – find the file: “Gbnetcfg.ini”.
If not exists – activate GreenLine, and then stop GreenLine.
Edit the file.
Find the line: “tcpcomm=“, change it to: “tcpcomm=TCP”

Save and close the file.
• At “.\Applic” folder – find the file “Tcpcomm.in”,

Rename it to “Tcpcomm.ini”,
Edit the file, write two lines:
[general]
port=3300
Save and close the file.
Note: You may choose different port number, but it has to be defined also at the
GPRS modem and the Port forwarding – see discussion hereby.
Activate GreenLine.
A gray “T” icon appears on the lower line:
If the TCP server succeeded to connect to a GPRS modem – the “T” color change to
green.
If you click on the “T” icon – a window opens:
At second line:
Clients: Number of TCP connected clients.
T: Accumulated number of bytes sent to the clients.
R: Accumulated number of bytes received from the clients.
6.11.3 Enable communication between GreenLine (on the PC) to a

GPRS modem
Following definitions has to be defined for the PC:

• The local port IP of the PC has to be set as a Fixed local IP.
• At the LAN Router: Port forwarding has to be defined for this Fixed local IP, with
port 3300.
Note: You may choose different port number, but it has to be defined also at the
GPRS modem and the “Tcpcomm.ini” file – see discussions hereby.
• Also – learn the Site External constant IP. It will be used for the GPRS definition –
see discussion hereby.

Define IP and port in GPRS modem model GenPro 25e:

Purchase a SIM card for GPRS modem from the local cellular provider.
• Connect the modem to the PC to the com port the GPRS modem will communicate
with. This connection is used only for the learning period.
• Activate ProgPlc, right-click on "Comm setup".
• Turn OFF the power of the GPRS modem, then close TCP server:
Hit on the “T” icon; On the open window - hit <Alt><X>, and confirm.
• Remove SIM card from the modem
• Put modem power ON and wait for messages to end (15 sec.)
If, for example:
The Site External constant IP is “213.155.102.107”, and the port number is “3300”:
• Set IP: AT+EGTSV=1," 213.155.102.107"
• Set Port: AT+EGTPT=1,3300
(The IP and Port number - saved automatically)
• Put modem power OFF.
• Insert the SIM card.
• Put modem power ON.
If all is OK, and the TCP server is ON, eventually (about 1 min) you will get a
"CONNECT" message on the ProgPLC display, and the gray “T” at lower PC line will
turned to be green.
6.12 EC/pH Monitoring System Installation and

calibration
This section describes the EC/pH system, how to install it, and the required
calibration procedures.
The EC/pH sampling cell collects and analyzes feedback water.
Water flows from the down-stream of the main line, after the fertilization line.
The sampling cell is shipped in 2 versions new version and previous version.
Calibration procedures are identical for both versions.
6.12.1 Sampling cell description – new version
In course of the calibration OK displays if the procedure is successful. During routine

operation the measured values are displayed.

Figure ‎6-43: Sampling cells mounted
To extract the sampling cell pull it downward with care.
Figure ‎6-44: Sampling cell extracted

To extract the electrodes pull out the electrodes from the housing as illustrated
below.
Figure ‎6-45: EC/pH electrodes extracted
6.12.2 Sampling cell description – previous version
Water flows from the down-stream of the main line, after the fertilization line.
The feedback water enters through the ball valve (see figure below), and exits to the
vacuum buster pump or Venturi pump.
The two electrodes (EC and pH) read the water content and send data to the EC/pH
controller, which sends it on to the PLC.
The ball valve is fully open during normal operation. Close it only to disconnect the
sampling cell from the feedback water, in order to calibrate the cell.

Figure ‎6-46: Sensors Sampling Cell
# Description
1 Ball valve
2 EC electrode
3 pH electrode
4 Outlet to vacuum buster pump or a Venturi pump
6.12.3 Installation procedures

Sampling cell components
The following figure illustrates the components of the sampling cell.

Figure ‎6-47: Sampling Cell Components
# Designation Description
1 EC electrode Measures the electrical conductivity in a solution.
2 pH electrode Measures the acidity in a solution.
3 Nut
4 Washer
5 Metal washer
6 "O" ring
Fully insert the EC and pH electrodes in their sockets, and then lock them into place
with the nut.
The metal washers slightly penetrate the electrode bodies, preventing high pressure
from forcing the electrodes out of the sampling cell.

6.12.4 EC/pH converter and transmitter description
The EC/pH converter and transmitter is supplied in 2 versions, with digital display
and without it.
Figure ‎6-48: EC/pH converter and transmitter with digital display
The EC/pH converter and transmitter device sends data from the sampling cell to the
controller.
The EC/pH converter and transmitter device contains a digital display, 2 LED
indicators and 5 buttons used during the periodic calibration procedure. The
calibration procedure details are below.
6.12.5 Connecting EC/pH converter and transmitter

The EC/pH converter and transmitter must be connected to the controller as
detailed below.

Figure ‎6-49: EC/pH monitor Interconnection schema
The EC/pH monitor front comprises terminal strips to connect it to electrodes and
controller as illustrated below.
The callouts in the illustration refer to the sequence numbers in the table.
‎6-50: CE/pH Monitor Front
# Designation Connected to Wire type Notes

1 Terminal PLC inputs: 0.8 mm² Data to PLC
EC, pH, Common
2 BNC type pH electrode Original
connector electrode cable
3 Terminal EC electrode Original Wire according
electrode wires to color list
4 Terminal Power supply 0.8 mm² 24 VAC power
24 VAC terminals supply

Wiring instructions:
1) EC/pH signal: Connect controller terminal 1 to the inputs terminal at the PLC: EC
terminal to EC input; pH terminal to pH input; Common terminal to Common “-“PLC
terminal.
2) pH electrode: Connect its original cable to the BNC connector on the controller.
DO NO CUT/CHANGE THE CABLE!
3) EC electrode: Connect the original four electrode wires to the controller terminal
3, according to color list on the terminal.
4) EC/pH controller power: Connect controller terminal 4 to PLC 24 VAC terminals.
Required tools: Wire stripper; Wire end sleeves; Screw driver.
6.12.6 Calibration procedures
Figure ‎6-51: EC/pH Converter and Transmitter
In course of the calibration a buffer can be used which is illustrated below.

Figure ‎6-52: EC/pH Calibration buffer
Pullout part of the content of the buffer into the sampling cell in course of the
calibration procedure. The buffer serves as a control solution.
Follow these steps to calibrate the EC/pH system:
Preparations
1. Verify that the power LED is on.
2. Open the lower cup of the sampling cell. Place a small cup (3) under the
calibrated electrode, as shown in Figure ‎6-53 below.
EC zero calibration:
1. Expose the electrode to the air, press and hold the EC 0 button.
2. After a few seconds, the status LED turns on and stays on.
3. Release the EC 0 button.
4. Wait a few seconds, until the status LED turns off. This indicates that the EC is
calibrated.
5. If calibration fails, the status LED blinks for 20 seconds.
EC 1.4 calibration
1. Put the electrode in a small cup of 1.413 buffer, then press and hold the EC 1.4
button.
2. Perform steps 2-5 listed in EC zero calibration above.
Setting the EC/pH controller for calibration at 1.4 and 5
1. Press and hold the EC1.4 and EC5 buttons simultaneously for 20 seconds.
2. Now place the electrode in a small cup of buffer of 1.4 or 5.


To resume to calibration at EC 0 and EC 1.4:
1. Press and hold the EC0 and EC1.4 buttons simultaneously for 20 seconds.
2. Now you can calibrate the controller with a small cup of a buffer of 1.4 and in the
air (0).
pH 7 calibration
1. Put the electrode in a small cup of 7.0 buffer, then press and hold the pH 7
button.
pH 4 calibration
1. Put the electrode in a small cup of 4.0, then press and hold the pH 4 button.
EC electrode maintenance
Open the sampling cell to maintain the EC and pH electrodes.
Once every 3 months, put the end of the EC electrode into 5% HCL solution for 5
minutes.
Do not touch the electrode surface with metal or sharp tools. Just wipe it with a
clean, wet cloth.
pH electrode maintenance
Once every 3 months, put the end of the pH electrode into 5% HCL solution for 5
minutes.
The pH electrode end is made out of glass, so be careful not to break or scratch it.
The predicted life cycle of a pH electrode is 1.5 to 2 years.

Figure ‎6-53: Sampling Cell Open
Notes
1. You must calibrate the EC/pH electrodes every three months.
2. Electrodes must be approved by Gavish before use.
Sampling cell flow nozzle

The flow nozzle provides a constant flow of the feedback water.
Figure ‎6-54: Sampling Cell Flow Nozzle
1 Female connector
2 Filter regulator nozzle
3 Male connector
4 Lock nut

Hydraulic Installation Procedures
7

7.1 General
This section describes the installation procedures of the hydraulic parts of the
system.
7.2 Plumbing Installation Instructions

Plumbing instructions depend on the deployment type installed: in-line, by-pass or
mixer.
However, the following general guidelines apply to all deployments:
1. Connect the FertiLine machine parallel to the main water line.
2. Connect the water from down-stream into the FertiLine water inlet.
3. Connect the water from up-stream into the FertiLine water outlet.
4. Connecting this way forces part of the water to create more than one
cycle, thoroughly mixing the fertilizers with the water.
5. Connect the EC/pH feedback pipe to the down-stream main line, about
three meters from the FertiLine, preferably after a filter or another mixing
element.
7.3 Tools
 Adjustable screw wrench
 Pipe wrench
 Plier wrench
 Big screwdriver
 Small screw diver

7.4 Pumps Installation

7.4.1 Fertilization pump
Fertilization pump components
Figure ‎7-1: Fertilization Pump Components
1 Non-return valve
2 Visual flow meter, transparent, with
orange float to displays the flow
2.a: "O" rings
3 Nipple
4 Ball valve to adjust the fert flow
5 Records
6 Solenoid valve. Uses to
enable/disable the fert flow
7 Fitting
8 Elbow

9 Fert counter with electric output

each 115 CC
9.a: Built-in net. Used as filter to
prevent solids from entering the
counter
10 Teeth connector. Used to connect
the flexible fert pipe.
11 Teeth nut. Used to tighten the
flexible fert pipe to the teeth
connector.
Note
The fert. counter has a numeric counter on its reading panel..
The pulsed-flow makes this count inaccurate. You may ignore!

7.4.2 Venturi pump

General
A Venturi pump is an ejector-jet pump that produces a vacuum by means of the
Venturi effect.
The Venturi pump illustration is given below.
Figure ‎7-2: Venturi Pump Overview and Cross Section
Figure ‎7-2 displays the Venturi pump.

Water at the high-pressure line flows from the upper inlet towards the vacuum
pressure at the lower outlet.
The water stream narrows and accelerates faster at the nozzle, then expands at the
cone inlet. This creates a vacuum at the cross axis, known as the Venturi effect.
This vacuum draws in the fertilizer to mix it with the water.

Opening the Venturi manifold for cleaning
Figure ‎7-3: Venturi Manifold
If the fert flow is too low, it is possible that there are foreign objects (plastic flakes,
Teflon strips, etc.) in the Venturi pump inlet.
To check and clean it:
Disassemble the manifold records, as displayed in the above pictures, and turn the
upper manifold by 90°.
Now you may inspect and clean the Venturi inlet.

7.5 Pressure and Vacuum Meters Installation

7.5.1 Pressure display
The pressure meters display the water and vacuum pressures of the fertilization
process.
Figure ‎7-4: Pressure and Vacuum Gouge
 The vacuum display shows the pressure level at the buster pump entrance.
Maintain this reading between -0.5 to +0.5 bar by adjusting the pressure.
You can adjust the pressure either by using the
1. "Pressure compensation valve"
2. "Pressure navigator"
 The pressure display shows the pressure of the main water line. Adjust it
according to the irrigation system specifications
7.5.2 Pressure compensation valve
Use the "Pressure compensation valve" to compensate for the lack of solution
flowing into the buster pump.
Connect it in parallel to the other fert pumps.
The lack of fertilizer solution results from changes in the total volume of water and
fertilizers during the fertigation process.

Figure ‎7-5: Pressure Compensation Valve

7.6 Low Pressure Switch Installation

7.6.1 General description
The pressure switch (pressostat) is illustrated below.
Figure ‎7-6: Low Pressure Switch - Pressostat
The pressure switch prevents the buster pump from working without water.

Figure ‎7-7: Low Pressure Switch
The low pressure switch measures the main-line water pressure, and disconnects the
pump in case of low pressure.
1 Differential setting screw
2 Protection plate
3 Pressure setting screw
4 Differential setting display
5 Pressure setting display
Pressure switch settings

Perform the following procedure to set the pressure.
1. Remove the pressure switch cover and the protection plate.
2. Set the pressure setting screw to 2 bars.
3. Set the differential screw to 0.3 bars.
4. Secure the protection plate and the pressure switch cover.
5. Verify pressure on the display.

The following manual trip functions assist you to reset the pressostat.
Figure ‎7-8: Pressostat Reset Trips

Communication Network Installation and Setup
8
Communication Network Installation and
Setup

8.1 General
An RS-485 network connects the controller and peripheral devices.
An Ethernet network connects the PC and the PLC.
You can connect multiple GreenLine View users to the network, as detailed below.
8.2 Connecting the PC to the Controller

Network protocols:
The system uses two communication protocols:
 RS-232, between the PC and the Gavish-85 communication converter.
 RS-485 (multi-drop), between the PLCs , and between PLCs and the Gavish-85
communication converter.
The Gavish-85 communication converter converts the protocols.
 The PC communicates through the RS-232 communication port.
 The PLC communicates through the RS-485 communication port.
Network cables:
The RS-485 network includes 2 wires, the "N" and the "P" wires.
 The cable type is NYY 2 X 0.75 mm², shielded, and grounded at one side.
 The RS-485 network cable length should not exceed 1000 meters.
If you require longer cable, you must add a "Gavish-86 Repeater" to increase
communication range.
PC, PLC and Gavish-85 wiring
Connect the Gavish-85 to the PLC using the RS-485 cable, to the to the Com 2 port
on the PLC.
Connect the PC to the Gavish-85 using the RS-232 cable,
On the PLC, define the manager and data transfer rate in PLC communication
definition window under Technician menu.

Figure ‎8-1: PLC Communication Definitions Window
Note
Verify that the PLC communication speed matches the data transfer rate on the PC.
The interconnection scheme is illustrated below.
Figure ‎8-2: PLC to PC Interconnection Schema

8.3 Connecting GreenLine View PCs to the Network

The network allows the PC to communicate with the controller (PLC). You can also
add more viewers and connect more PCs to the main GreenLine PC to share
information, including data, screens, reports and graphs.
Simultaneous operation on the GreenLine application of every PC in the View PC
network does not interrupt the operation of any of the PCs in the network.
8.3.1 Network deployment
The GreenLine View system includes a server PC and client PCs connected over a
LAN.
The server PC must be continuously powered on to collect data through the RS-485
network from the PLC. You can connect client PCs to the server at any time.
Data exchange between the server PC and the clients' PCs is based on a client-server
protocol.
You must connect the server PC and client PCs to a common LAN workgroup using
Ethernet cables, plugged into a hub or a switch. If there is only one client PC, it can
be connected to the server PC via a peer-to-peer cross-wired network cable (no LAN
and hub or switch required).
LAN wiring is limited to about 100 – 150 meters. For longer distances, you must
install fiber optics cables and terminals.
Below are typical LAN deployments scheme.

Figure ‎8-3: Multi-Viewer Deployment
Note
The software installation procedure is detailed in the Spirit Pro PC User Guide Appendix.

Post-Installation Preliminary Test
9

9.1 General
After installing the system and before starting routine operations, perform the
following tests to verify its functionality.
9.2 Testing inputs and outputs

To test the functionality of the controller and inputs and outputs access the
Technician definition screens on the controller and select Inputs/Outputs option.
Figure ‎9-1: Inputs/Outputs definitions
Perform the tests listed below. In course of the tests enter the applicable screen on
the controller panel as listed to examine results.
9.2.1 I/O cards tests
Note: the device indicating LEDs for digital inputs or outputs lit only if the relevant
device is operational. For analog inputs the LEDs do not lit.
Test Test device Test procedure Screen

objective
Communication Check communication.

test
Examine communication status LEDs:
The two LEDs at left are green.
“ON”‎is‎a‎sign‎of‎“power‎supply”‎(light=OK).
“Run”‎is‎a‎sign‎of‎the‎chip‎status‎(light=OK).
The next LEDs are red.
“RX1”‎indicates‎communication at communication

port 1.
“TX1”‎indicates‎transmitting‎at‎communication‎
port 1.
“RX2” indicates communication at communication
port 2.
“TX2”‎is‎a‎sign‎of‎transmitting‎at‎communication‎
port 2.
Note: TX2 and RX2 are generally not used.
Figure ‎9-2: Communication indicators
Digital output Multi-tester Enter Output status screen set the applicable Output
output to manual mode. status
To start the device press OK on the keyboard,

verify that the screen changes from OFF to ON.
Start output and verify that the corresponding
output LED on the I/O card lit. Examine that the
connected device works.
If the device does not work, cheek the LED. If the

LED does not lit:
- Check communication between CPU and I/O
card
- Select another output on the card.
- LED lit and the devise does not work check the
fuse of the output.
- If fuse burns check short circuit on the device.

- If fuse OK and devise not operational test on the

terminal strip between N and Out for 24 VAC.
Exceptional for: 13, 14,15 16
If standard 24 VAC applied test between common
and the jumpers for 24VAC.
If used for dry contact output not active readout
should show infinitive residence,
If active short circuit.
Digital input Multi-tester If communication OK, check jumpers. Digital

Inputs
Enter Digital Inputs screen.
Verify the all green jumpers on the I/O card and
all minus connection are connected to 0VDC.
Connect between + 12 VDC and + input via a
wire.
Enter Analog input status screen, check bits and
look for faulty value entries.
In Analog input definitions screen check
4 mA and 20 mA readouts. (4 mA = 0 bit, 24 mA
– 1023 bit)
If LED lit check on the screen if + displays next to
the input tested.
If LED does not lit the input port is not functional.
If LED lit and + does not displays on the screen
check jumpers.
Analog input Multi-tester Enter Analog inputs status screen. Check jumpers. Analog
Check for 24 VDC between 24 VDC and 0. inputs
Readout should be between 24 ~ 31 VDC. If OK status
bit readout displays on the screen.
If not, test readout between 0VDC and input +,
1~ 5VDC.
Analog
Screen readout does not change check the device. input
definitions
If analog input not appropriate disconnect input wire on the I/O card for resistance
test. Screw the fastening screw of the disconnected wire. Test resistance between
OV and ground terminals. Read out 249 .

Figure ‎9-3: Resistance test - Setup

Figure ‎9-4: Voltage test - Setup

Figure ‎9-5: Testing voltage at test points
If all analog inputs fail connect the Multi-tester to TP1 (1 VDC) and GND, and TP2 (5
VDC) and GRD. Use the potentiometers next to the TPs to adjust the voltage.
9.2.2 Extension cards test
Test Test Test procedure Screen

objective device
Digital Input Multi-tester If green LED (1) indicator not lit check cable Digital
extension between I/O card and extension card. Inputs
card status
Set short circuit between 12 VDC (2) and -7 (3)
and verify that the relevant digital input
indicator LED (4) lit.
If the LED lit check Digital Inputs staus screen
to verify that the + signs displays at the
relevant input.
Otherwise check I/O card or replace extension
card.

Output Check fuses.

extension
If red LED indicator not lit (1), check fuse (2)
card.
If fuse OK, check cable between I/O and
extension cards. Otherwise, check extension
card.
Check output indicator LEDs (4). If not lit check
output terminator fuse (3) and voltage
terminator (4) for 24 VAC.
Verify that green LED (5) indicating 12 VDC
supply lit continuously.
Verify that red LED (6) indicating 6 VDC supply
lit continuously.
Check I/O card.
Figure ‎9-6: Analog extension card

Figure ‎9-7: Digital input card
9.3 Testing the CPU card

In case of need you may check connections and voltages as illustrated below.
Figure ‎9-8: CPU card test

# Description Notes
1 12 VDC input test Perform test as illustrated
2 RS-485 voltage test Perform test as illustrated
3 RS-232 chip
4 RS-485 chip
5 RS-232 voltage test point Perform test as illustrated
6 RS-485 voltage test point Perform test as illustrated
7 Connector and cable to display
8 Connector and cable to LED card
9.4 Testing PC inputs

If the system comprises also the GreenLine PC application in addition to the
controller, perform the following also:
Test the communication between the controller and the PC.
In case of fail, test the Gavish 85 and the connections toward the controller and the
PC. Check communication setting at the controller and at the PC.
9.5 Functional Tests

9.5.1 General
This test is a step-by-step check of the overall functionality of the fertigation system.
9.5.2 Irrigation system test
Perform test procedure by the following steps:

1. Start the main buster pump manually when the field valves are open
2. Close the field valves gradually to increase pressure about 1 bar above the
predefined working pressure
3. Use the Pilot bolt on the PSR valve to reduce the pressure to the predefined
working level – illustrated below.
4. Open the water inlet and water outlet manual valves until the readout on both
pressure gauges shows the required pressure
5. Start manually the main buster pump and verify that it runs in the right direction
according to the arrow on the pump
6. Verify that the readout on both pressure gauges shows 0 bar or close to it

7. Test fertilization flows in the fertilization suction column (Visual flow meter) and
in the fertilizer counters, when manual valves on the columns are completely
open.
8. If air bubbles come into the fertilizer suction column check for leaks and tighten
all connectors and nuts
Figure ‎9-9: Pressure Sustaining Valve

Software Download and Update
10

10.1 General
A Spirit Pro PLC may be reprogrammed, in order to upload new versions or to add
new features.
In order to program the Spirit Pro PLC – you have to follow the next steps:
 Receive and install the distribution kit on a PC.
 Activating “ProgPLC” program.
 Send program to the Spirit Pro PLC.
This section also includes:
 Troubleshooting communication failures.
 Sending program to I/O card.
10.2 Receive and install the distribution kit.

Distribution kit of Spirit Pro Irrigation AcDc may be sent on a CD, or through Email.
It contains two setup files:
“GreenLine Setup.exe” and “Spirit Pro Irrigation AcDc Setup.exe”.
Before activating the setup files, in case a GreenLine application already installed on
the PC – you have to create a “Photo” of the set points as follows:
a. Activate GreenLine.
b. At the top bar of GreenLine – select the Diskette icon:
Figure ‎10-1: GeenLine – Top bar
c. At the opened Backup, Restore window - select on the Camera icon:
Figure ‎10-2: Backup, Restore window
d. After you got a message “Gavish.zip file created” close the window.
e. Press <Alt><X> keys to exit the running application.
10.3 Activating “ProgPLC” program

You have to activate two setup files, starting with “GreenLine Setup.exe”.

a. Using the Windows Explorer – enter the Applic directory.

Normally it is located at: “C:\Gavish\GreenLine\Applic”.
Select “2 PLC” icon:
Figure ‎10-3L GreenLine\Applic window
ProgPLC program window opens:
Figure ‎10-4: ProgPlc window
b. First – set the PC communication parameters:

Select “19. PC comm setup/viewer” to display the PC com setup window:

Figure ‎10-5: PC comm setup window
Define the correct communication port on the PC.

You may use Windows “Device manager” tool to allocate the port number.
If you use USB-to-Serial adaptor –check the USB cable checkbox.
c. Connect the PC to the PLC:
You may use two communication methods to connect between the PLC and the PC:
1) RS-232 protocol:
If you just have to send the program to the PLC - the RS232 protocol suffice.
At the PC - connect a “USB-to-Serial” adapter, (E.g.: Aten UC-232-A) to a USB port.
Get the RS232 cable (supplied by Gavish), connect it to the PLC Comm1 , as
illustrated below:
Red wire to N, Black wire to P, Silver wire to the GND:
Figure ‎10-6: Connecting RS-232 cables

2) RS-485 protocol:
If you need to send operating system (Kernel) to the PLC – you must use RS-485
protocol. This connection may also be used to send programs to the PLC.
For RS-485 - you have to use a Gavish-85 communication converter, wired as follows:
At the PC - connect a “USB-to-Serial” adapter, (E.g.: Aten UC-232-A) to a USB port.
Pull the RS-232 cable (supplied by Gavish), to connect it to the Gavish-85, as follows:
Red wire to Tx, Black wire to Rx, Silver wire to the SG:
Figure ‎10-7: Connecting Gavish 085
Pull the RS-485 cable (supplied by Gavish) from the Gavish-85 to Comm2 of the PLC.
On the Gavish-85 - connect Red wire to P, Black wire to N.
At the PLC – connect the cable plug into the external socket labeled as “Comm2”.
d. In order to check the proper communication wiring – right-click on:
“16. Search for PLC / Ping”.
If the wiring is OK - you will get a message “Ping OK”.
If you get “Ping timeout” message – please see “Troubleshooting for communication
failure” below.
e. If it is not a first time installation – the PLC application definitions have to be saved
on it.

In order to read and save those definitions – select “17. Read data from PLC”.
At end of this session – the program suggest a file name to save the definitions.
Accept it.
f. In order to send operating system (Kernel) to the PLC – Select on “13. Send op.
system to pic PLC”.
10.4 Send program to the PLC

a. At the right pane–select the relevant line according to required language (English,
Hebrew, Spanish, and etc.)
At left pane– select “2. Send program to PLC”.
During the session – circles display on the screen, showing the progress of the
procedure.
At session end –expect a message “PLC 1 programmed and verified OK”.
b. In order to put back the kept definitions:
1) Select “18. Write data to PLC”.
The program will ask for the file name. Select the file applicable.
After you put back the definitions – reset the PLC as follows.
2) Select "1 PLC menu" to display the dropdown list:
Figure ‎10-8: PLC menu
Select “Reset PLC” option. Wait for “Reset OK” message.

Close the ProgPLC window.
Now PLC is programmed!

10.5 Troubleshooting for communication failure

In case “Ping timeout” message displays:
1. Use Windows “Device manager” tool to make sure that the communication port
number is correct.
Verify that the port number defined correctly, select “19. PC comm, setup/view”
option.
2. If you use USB-to-Serial communication – verify that the USB-Cable checkbox is
marked at “19. PC comm, setup/view” option.
3. Check the PC communication card, as follows:
The PC communication port connector is a “9-pins male connector as illustrated
below.
Figure ‎10-9: DP Male connector
Temporarily set up a short circuit between pins 2 and 3.

Select “14. PC comm. port test”.
If the PC communication card is OK – a “Test OK” message displays.
If PC communication card is not OK – a “Test failed” message displays.
10.6 Send program to I/O card

The need to send program to the I/O card is very rare, but might be required due to
version updates of the I/O card software.
I this section, we will instruct you how to perform it.
It is very important to follow all of the instructions carefully, step-by-step.
1. Activate “ProgPLC” program.
You may activate it at “..\Applic” folder, - activate the shortcut “2 PLC”, or increase
you access level to “manager” at GreenLine application and select the icon of
ProgPLC at the top bar.

The following window opens:
Figure ‎10-10: ProgPlc window
At the right pane- select “1 Spirit Pro Irrigation”

At the left pane <Right click> “19 PC comm setup/Viewer”
2. The “Spy” window opens:
Figure ‎10-11: The Spy window
Select the button marked above by the red square.

3. A new window “Connect coms in PLC” opens:
Figure ‎10-12: Connect coms in PLC window
a. Hit on Pause PLC command button

b. Select the Control option button

c. To the left of “by com” command button enter 4
d. To the right of “by com” text enter the port number you selected on the Spirit-Pro
PLC
(If RS-485 –enter 2, if RS-232 –enter 1)
e. Hit on “Connect” button
f. After you see the message , close the “Connect coms on PLC”
window.
g. Close the “Spy” window.
Now you are back at ProgPLC window.
4. At ProgPLC window perform the following:
Figure ‎10-13: ProgPlc window A
a. On right pane– select “101 Spirit IO unit 1”.

b. On left pane select “2 Send program to PLC”.
c. Wait until the procedure is completed and a message “PLC 101 programmed and
verified OK” displays at the bottom line.
If additional I/O cards connected to the Spirit Pro PLC – select them one by one at
the right pane, and repeat steps b, c for each I/O card.
d. Now, at the right pane mark the line “1 Spirit Pro irrigation”:

Figure ‎10-14: ProgPlc window B
At the left pane <Right click> on “19 PC comm setup/Viewer”.
5. At “Spy” window, select the icon.

6. A new window “Connect coms on PLC” opens:
Figure ‎10-15: Connect coms on PLC window
a. Hit on “Hot reset” command button.
b. After you see the message , close the “Connect coms on PLC”
window.
c. Close the “Spy” window.
Now you are back at ProgPLC window.
Close the ProgPLC window.
Now the I/O card is programmed!

Periodic Maintenance Directives
11

11.1 General
The technician’s periodic maintenance cycle is listed in the table below. Use the
illustrations marked in the table to locate assemblies and parts.
Interval Machine Part Procedure Sequences Tool Fig.
Daily Fert pumps flow Inspection

Vacuum level Inspection Adjust to
0.5 to 0.0.
Water supply Inspection
pressure
Irrigation flow Inspection
Fert tanks filter Flush by water
Machine Inspection
leakage
Communication Inspection
Monthly Fert pump Cleaning Flush with
water
Disk filter (in- Cleaning Disassemble, 5-4
line machine clean with
only) brush and
water
Fert flexible Inspection
pipes
Semi Meteorology Cleaning
Annual station Rain cup cover
Radiation cover
Annual pH electrode Replacement 6-27
EC electrode Replacement 6-27
Inter-crop Fertigation Between crops

and inter machine and seasons,
flush the
season machine with
procedure clean water to
avoid
crystallization of
fertilizers and
other materials

Troubleshooting
12
Troubleshooting

Troubleshooting
12.1 General
The following tables list possible symptoms and suggested corrective actions.
12.1.1 Alarms Analysis
Symptom Possible cause Remedy
Unexpected There are several reasons that may stop The reason detailed in Alarm
stoppage of irrigation. screens, in Events screens, in
irrigation Last irrigation of the head, Last
irrigation of the program.
Fertilization ratio a. The fert pump stopped working – due to a. Verify that the fertilization
differs from the fertilization level limits. limits are logical.
planned one b. The fert pump flow rate is not enough – b. Reduce fertilization solution
for the required fert flow rate. dilution.
High water flow a. Pipe break. a. Look for pipe break.
b. Flow rate definitions not accurate. b. Activate each valve separately
and monitor its actual flow rate.
Low water flow a. Valves not open. a. Verify that all valves are open.
b. Poor water supply. b. Look for water supply failures.
c. Flow rate definitions not accurate. c. Activate each valve separately
d. Water counter internal filter cloaked and monitor its actual flow rate.
partially. d. Open water counter
connector and clean filter
No water flow a. Valves, main valve, pumps – not open. Check irrigation supply, main
valve, field valves.
No fertilization a. Fert tank is empty. a. Check and clean all fert pipes,
pulses b. Filter in fert tank outlet is clogged. pumps, accessories.
c. Fert pump or accessories are clogged. b. Check fert counter.
d. Fert pulse counter failed. c. Check fert pulse volume
e. Fert pulse volume not defined. definitions.
f. FertCounter filter clocked d. Open water counter
connector and clean filter
Fertilization a. Fert pump leaking. a. Clean and tight the fert pump.
leakage b. Fert solenoid failed to close. b. Clean or replace the fert
solenoid.
Fertilization pulses See “No fertilization pulse” above
missing
Filter flush a. Water contains too much mud. a. Check the reason for too much
reiterations b. D.P. failure mud in the water.
b. Replace D.P. sensor.
Water leakage Water break Look for water break.
Extreme EC/pH a. Wrong definitions of EC/pH extreme a. Check the extreme fertilization
levels levels definition.
b. Fert pump is operating on extended b. Check the definitions of the
period. ON time of the fert pump.

Troubleshooting
12.1.2 General Symptoms

Symptom Possible cause Remedy
Fuse burned Electric short circuit of connected Change fuse. Ensure that the
elements. same fuse definitions are kept.
Look for short connected
elements.
Fuse map is provided in section
5.
Low Battery Dirt caused battery leakage. Change battery. Keep same
battery type (battery type CR
2032 3V).
Low water pressure a. Poor water supply a. Check water supply.
issues b. Wrong settings of low pressure b. Check low pressure settings.
sensor (pressostat).
High water pressure a. Poor water supply a. Check water supply.
issues b. Wrong settings of high pressure b. Check high pressure settings.
sensor (pressostat).
Controller a. Communication wiring failure. a. Check the wiring. Look for 0.8
communication b. Communication chips in PLCs failed. VDC between N-P (RS 485).
outage b. Replace communication chips
in PLCs.
Power supply outage Power is off or incorrectly connected to Check the power supply.
the controller.
Valves do not open a. Solenoid did not get Open command. a. Activate the valve by manual
b. Failed solenoid. command. Measure the voltage
on the valve’s wires.
b. Replace the solenoid.
Note: if the valve is an AC valve,
it should measure 24 VAC.
If the valve is connected over
RTU, voltage readout is
problematic and you should
replace the solenoid.
Valves do not close a. Solenoid did not get Open command. a. Activate the valve by manual
b. Failed solenoid. command. Measure the voltage
c. physical obstruction (rocks or other on the valve’s wires.
debris) preventing the diaphragm from b. Replace the solenoid.
seating c. Disassemble and clean the
valve parts.
Display blank a. Internal video cable disconnected. a. Open the PLC cover, check
b. LCD display failure. video connecting cable.
b. Replace the LCD display.
Frozen display PLC failure. Reset the PLC.

Troubleshooting
12.2 Inspect your system for leaks

If the water consumption of the system grows check pipes, valves, fitting etc.

Parts List and Replacement Policy
13

13.1 General
This section lists the site replaceable spare parts. These parts can be replaced by the
technician at site. It is recommended to stock these parts at site in order to replace
faulty parts and return the system into operation quickly as possible.
Hydraulic parts - Recommended parts list
Fertilization pump components
Figure ‎13-1: Fertilization Pump Components
# Designation Quantity
1 Non-return valve 1
2 Visual flow meter, transparent, with orange float to 1
displays the flow 2.a: "O" rings
3 Nipple 1
4 Ball valve to adjust the fert flow 1
6 Solenoid valve. Uses to enable/disable the fert flow 1
9 Fert counter with electric output each 115 CC 1
9.a: Built-in net. Used as filter to prevent solids from
entering the counter

Electric parts– Recommended parts list
Device / IC Part Code Quantity Notes

No.
Glass fuse 24VDC- 1A Fuses 5
Glass fuse 24VDC- 2A units for
Glass fuse 24VDC- 5A each
bus fuse for each output 2A type
Communication IC 1
I/O card 1
Output extension card 1
Input extension card 1
EC/pH monitor 1
EC electrodes- passive 1
pH electrodes The life span of the pH electrode is
limited and can be shipped only on
request
Display (controller) 1
CPU 32 (controller) 1
Mini relay with LED 1
Meteorology station card 1
Ventilated cell 1
Temperature sensor 1
Radiation sensor 1
Wind speed and direction 1
cell
Rain counter 1
Temp/hum sensor 1
Gavish 85 card 1
LED card 1

Spare parts replacement
14

14.1 General
This section contains instructions for disassembly and replacement of defective
parts. Disassembly is limited to the removal of parts followed by assembly
instructions.
14.2 Warning
Replacement activities should be performed only after the main power
inlet is disconnected.
14.3 Display card and display replacement

Disassembly
a. Disconnect cable (1)
b. Unscrew 4 fastening screws (2)
c. Lift the card
Figure ‎14-1: Display and display card disassemble
Assembly
Perform above steps in reverse order.
14.4 CPU Card replacement

Disassembly
b. Disconnect cable (2)
c. Mark up wires (3)

d. Unscrew 6 fastening screws (4)

e. Extract wires
f. Extract the card
Figure ‎14-2: CPU card disassembly
Assembly
Configure the card ID via the controller.
14.5 LED card replacement

Disassembly
b. Unscrew 4 fastening screws (2)

Figure ‎14-3: LED card disassembly
Assembly
14.6 I/O card replacement

Disassembly
c. Disconnect circuit breaker (1)
d. Mark up wires (2)
e. Disconnect cable (3)
f. Disconnect cable (4)
g. Unscrew 6 fastening screws (5)
h. Extract all wires (2)
i. Extract card

Figure ‎14-4: I/O Card disassembly
Assembly
Configure the card ID via the controller.
14.7 Output extension card replacement

Disassembly
b. Mark up wires (2)
c. Write down DIP switch settings (3)
d. Extract all wires (2)
e. Unscrew 4 fastening screws(4)
f. Extract card

Figure ‎14-5: Output extension card disassembly
Assembly
Set DIP switch.
14.8 Input extension card replacement

Disassembly
b. Mark up wires (2)
c. Unscrew 4 fastening screws(3)
d. Extract card

Figure ‎14-6 Input extension card disassembly
Assembly
14.9 Meteorology card replacement

Disassembly
b. Lift terminator cover (2)
c. Lift terminator cover (3)
d. Unscrew 4 fastening screws(4)
e. Extract card

Figure ‎14-7: Meteorology card disassembly
Assembly
Perform steps in reverse order.
14.10 Ventilation cell replacement

Open the cover of the external box and unscrew 4 fastening screw to release the
inner box cover and to access the ventilation card.
Figure ‎14-8: Ventilation cell – external box

Disassembly
a. Unscrew 2 fastening screws(1)
b. Release wires (2)
c. Extract the box
Note: Do not disassemble the electronic card.
Figure ‎14-9: Ventilation cell card disassembly
Assembly
14.11 Gavish 85 card replacement

Disassembly
a. Disconnect power cable from the wall outlet
b. Disconnect communication cables
c. Unscrew 2 fastening screws (1) on the front
d. Release the cover (2)
e. Test two 0.5 A fuses (3)

f. Unscrew 4 fastening screws(4)

g. Lift the card with the power cable (5)
Figure ‎14-10: Gavish 85 Card replacement
Assembly
14.12 Meteorology Station Replacement

The meteorology station devices are mounted an attaching base mounted on a pole.
The following illustration shows the attaching base before mounting the
meteorology station devices and after.

Figure ‎14-11: Meteorology Station - Assembled

Figure ‎14-12: Meteorology Station with lightening protector
To dissemble any devise mounted on the attaching base, lower the pole and
disconnect cables at the meteorology card with care and unscrew fastening bolts,
washers and screws of the device.
14.12.1 Wind speed and direction meter
The disassembled wind speed and direction meter (anemometer) is illustrated

below. For disassembly and assembly procedures follow the instructions given in the
vendor's booklet.

Figure ‎14-13: Anemometer - Disassembled
14.12.2 Radiation sensor
The radiation sensor and connecting cables are illustrated below.

For disassembly and assembly procedures follow the instructions given in the
vendor's booklet.
Figure ‎14-14: Radiation sensor

14.12.3 Rain collector
The rain collector is illustrated below. The rain collector contains two main parts,
the tank and the base.
For disassembly and assembly procedures follow the instructions given below.
Figure ‎14-15: Rain collector – Side view
The base of the rain collector mounted on the plate is given below.

Figure ‎14-16: Rain Collector base on pate
To release the rain collector tank from the base, hold the base and turn the tank
contra clockwise and lift it.

Figure ‎14-17: Rain Collector base with callouts
On the base perform the following steps:

a. Adjust the circular level (1)
b. Unscrew 4 fastening screws (2) to lift the base from the plate
c. Release the yellow snap shackle (3)
d. Screw 4 fastening screws (2) to attach the base to the plate
e.. Place the tank on the base. Verify that the four ogees (4) match the four ridges
of the tank and turn it clockwise to tighten it
e. Place the protective net on top of the tank
f. Place the rain collector on the plate and tighten it to the pole by means of four
nuts
g. Connect cables to the meteorology card.

GAVISH CONTROL SYSTEMS LTD.
Kibbutz Naan 7682900 Israel.

Tel/Fax: 972-8-9372036
E-mail: info@gavishcontrol.com
Website: http://www.gavishcontrol.com

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GAVISH CONTROL SYSTEMS LTD.

Kibbutz Naan 7682900 Israel.

Spirit Pro Technical Manual

Spirit Pro Technical Manual II

Block Diagram Description .........................................................................................................5

Unpacking and Placement .......................................................................................................10

Fertigation House Setup ..........................................................................................................14

Spirit Pro Technical Manual III

Electronic Installation Procedures ............................................................................................57

Spirit Pro Technical Manual IV

Hydraulic Installation Procedures ........................................................................................... 100

Communication Network Installation and Setup ..................................................................... 111

Spirit Pro Technical Manual V

8.2 Connecting the PC to the Controller .......................................................................................... 112

Post-Installation Preliminary Test ........................................................................................... 116

Software Download and Update ............................................................................................. 127

Periodic Maintenance Directives ............................................................................................ 137

Troubleshooting ..................................................................................................................... 139

Parts List and Replacement Policy ......................................................................................... 143

Spare parts replacement ........................................................................................................ 146

Spirit Pro Technical Manual VI

14.7 Output extension card replacement........................................................................................... 150

Spirit Pro Technical Manual VII

Spirit Pro Technical Manual VI

Figure ‎6-3: Spirit Pro Terminal Strip Wiring Scheme B ..............................................................61

Spirit Pro Technical Manual VII

Figure ‎6-53: Sampling Cell Open ............................................................................................99

Spirit Pro Technical Manual VIII

Figure ‎14-14: Radiation sensor ............................................................................................. 158

Spirit Pro Technical Manual IX

Spirit Pro Technical Manual

1.1 About Gavish

1.2 About Spirit Pro Irrigation System

1.3 Safety Summary

Spirit Pro Technical Manual 2

1.4 About this Manual

Section 1 Describes the Spirit Pro irrigation system and introduces

Section 2 Describes the basic structure and functions of the Spirit

Section 4 Describes how to safely set up a typical fertigation house

Section 5 Describes the Spirit Pro system and provides illustrations

Section 8 Describes how to connect PCs to the Spirit Pro PLC

Section 6 Describes installation procedures of the electronic

Spirit Pro Technical Manual 3

Section 7 Describes the installation procedures of the hydraulic

Section 8 Describes how to connect PCs to the Spirit Pro PLC

Section 9 Describes the tests that verify system functionality after

Section 10 Describes downloading the PLC controller program to site

Section 11 Describes the periodic maintenance cycle.

Section 12 Lists troubleshooting instructions based on symptoms and

Section 13 Lists the replaceable spare parts and replacement policy

Section 14 Describes the replacement procedures of field replaceable

1.5 Applicable Documents

Spirit Pro Technical Manual 4

Spirit Pro Technical Manual 5

2.1 General Block Diagram

Figure ‎2-1: General System Block Diagram

Spirit Pro Technical Manual 6

2.2 Irrigation System Logic

Figure ‎2-2: Irrigation System Overview

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2.3 Controller Front Panel

Figure ‎2-3: Control Panel – Front View