Corkill Systems AGFIRST User manual

AGFIRST
ENGINEERING .
EFFLUENT
CONTROLLER
2022
Instruction
&
Installer’s
Manual
Manufactured by
Corkill Systems Ltd
“specialists in Aut omation Solutions”
5 Tasman St, PO Box 16 Opunake, Taranaki, New Zealand.
Phone [phone] Fax [phone]
Email : [e-mail]
A Telarc Q-base registered company

AGFIRST
EFFULENT CONTROLLER
INSTRUCTIONS
AND INSTALLERS MANUAL
The Agfirst effluent irrigation controller as a total standalone controller able to
automate and protect the components of the effluent system.
INTRODUCTION
The AGfirst effluent irrigation control system is driven by a Crouzet Millennium Smart Logic
controller which Controls the motors of the effluent system to provides protection for both the
system and the environment.
The system is C-Tick/RCM Compliant and runs of a Three phase supply (neutral not
required).
The system consists of a main control box fitted beside the irrigation pond and comes with a
remote station to mount in a position to make it easier for the operator to control.
Additionally, the system May be fitted with a variable speed drive for pump motors exceeding
7.5KW, If supplied the system will come with a Danfoss FC 202 Aqua dive.
It is not recommended to connect the unit via an Earth Leakage device (RCD) (but if required
to install the unit on an RCD the use of a type A/B RCD is required to avoid nuisance
tripping); the controller monitors earth constantly to protect the motors and has an earth
leakage of approximately 8 milliamps. Nuisance tripping of the RCD’s can be rectified by
turning of the internal RFI filter within the drive.
INSTALLATION
The Main Controller The supply cable is intended to be run directly to the main control from
the supply and the terminations for the main pump (VSD or DOL) and the stirrer motor all wire
back to there
The Remote Push-Button Station. The Multi-core cable between the remote station and the
main control box requires 10 cores are required and the use of 1.5mm 11c+E is typically
recommended to avoid volt drop of note all the control signals are 24vdc low voltage.
It Is advisable to run the cable inside conduit or Alkathene so this cable can easily be
replaced in future, Connections are as per the numbers in the cable and at the connections in
the Main Junction Box and the Main Control Panel.
The Harvest connection. The harvest terminals are for connection to a remote monitoring
and control device such as a Harvest ITU terminal for control of the system from a smart
device remotely.

The kelco E30. A Kelco E30 is used as pump protection in sandy areas and has output for
fault to stop the controller on over or under pressure and a priming function to open a
solenoid valve to protect the pump from running dry, it requires 5 cores and typically a 7c+E
.75 mm is suitable. station and the solenoid valve connects directly to it.
The kelco F60. A Kelco F60 is used as pump protection and has output for fault to stop the
controller on over or under pressure and a priming function to open a solenoid valve to protect
the pump from running dry, it requires 5 cores and typically a 7c+E .75 mm is suitable.
The Danfoss VSD the VSD (if supplied) it to be supplied with circular TPS 3c+Eare to be
wired in EMC type screened cable using steel glands to connect the cable screens at both the
drive and the terminal box to comply with C-Tick/RCM requirements. The earth conductor
MUST also be attached at both ends. The motor must be wired in 400v configuration.
An example of a metal gland shown below.
Installation of metal glands and screened cables is an essential factor in lowering the SCC in
the dairy plant.
The minimum size of the conductors to the motors should be 1mm. Do not undersize cables,
larger is better to assist removal of RFI.
The above is also critical if cow ID systems are in use or being contemplated. The screen
should be retained over the cable as close as possible to the termination.
The Crouzet Smart Relay The main controller contains smart relay that can be used to
adjust a few settings of the controller, an easy-to-understand user interface is installed into
the plc.
By pressing the “A” or “B” button the various timer values can be adjusted by pressing the
“OK” button on the desired timer to adjust the value “OK must be pressed again to store it in
and the next time the system is started the new values will become the default settings.
Use the up and down arrows to edit and change menu items.
below is a list of menu items:
pump max run trip
safety timer to stop the pump sequence if the pump fails to complete its sequence within the
allowed time.
pump fail to start timer
safety timer if the pump fails to start will stop the pump sequence
pump fail to stop timer
safety timer if the pump fails to stop the pump sequence.
stir fail to start timer
safety timer to stop the Stir sequence if the pump fails to start fails.
stir fail to stop timer
safety timer if the Stirrer fails to stop when the stir sequence has finished.

flow switch fault delay timer
fault delay to ignore the flow meter’s fault signal for a specified time.
Pump Start Delay
Delay timer to allow the stirrer to agitate the pond before starting the pump.
Use VSD as pump
switch the control cabinets operation to run either a VSD or DOL pump
Force power to Kelco
force power to the Kelco switch when the system is not in operation to enable programming
Bypass remote timer
Bypass the external pump run timer so the system runs off the max run timer.
(Enables testing if the remote-control box has not been fitted and bypass in case of failure of
the remote timer)
Max Trips in Period
This is used to stop the system from repeated reset upon multiple faults fault once the reset
counter is reached it will require a hard reset to re-enable operation (depower the controller or
hold the reset button for 10 seconds)
Trips Period
The time period for the max trips in period counter the counter will be reset at this interval.
Harvest Bypass
Used to ignore faults from the harvest system if it is offline or not fitted.
Time clock programming
A. If power supply is disconnected press “OK” for one second. The display appears in
Automatic-Mode.
B. Press “M”, the time switch is now in the Enter-Mode.
C. Confirm Program with “OK”.
D. Confirm new program with “OK”.
E. Choose the desired channel with “+” and or “-“ and confirm with “ok” .
F. For regular switching times choose on or off with “+” and “-“buttons and confirm with
“OK” .
G. Within this level you activate the days of the week (1…7) on which the switching time
should happen.
With “+” and “-“ you activate “yes” or deactivate “no” the corresponding date. Confirm
each day with “OK”.
H. Adjustment of the time: you may press “+” and “-“ to adjust the hours and Press ”OK”
to advance to the Minutes and adjust in the same way.
I. Verify the entered switching time: If the flashing summary of the programming step is
correct, verify on or off with “OK” . After verification you have the choice between
edit/delete and end with “+” and “-“ .
J. If you want to proceed with programming, confirm next switching with” OK” To leave
the programming menu confirm end

Manual time clock bypass
By pushing “A” and “B” buttons or “+” and “-“ buttons simultaneously manual operation of the
channels take place. The resulting switching status is marked
with the hand-symbol and remains until the next programming
step occurs. (temporary over-ride)
Permanent switching status P
By pressing the corresponding channel button for more
than 3 sec. the channel is permanently switched ON or OFF.
The status remains until the next manual switching occurs (> 3
sec.). (permanent over-ride)
Harvest Option
The harvest option is for integration of a Harvest Remote telemetry system.
The outputs of our controller are voltage free referenced to the common terminal.
The inputs of our controller are active high reference to the DC supply.
The inputs info the AGfirst controller operate as follows:
Pump start /stop (pulsed) triggered on diff up
Stir start /stop (pulsed) triggered on diff up
Trip ( pulse or latch, expect active in trip condition)
Reset ( pulse for normal reset held for 10 seconds for hard reset)
The outputs from the AGfirst box are as follows
Trip indication (Closed to indicate a trip condition)
Pump Indication (pulse sequence or solid to indicate status)
Stir Indication (pulse sequence or solid to indicate status)
Reset indication (Closed to trigger a reset has been made to the harvest system)
Note: the contactors contained within this unit are rated for 7KW.
Please check the overload ratings are of the correct size for the motors prior to
installation, also Included with in the controller is a breather unit to stop
condensation forming please fit it underneath the remote-control cabinet during
installation.

CORKILL SYSTEMS LTD
5 TASMAN ST, OPUNAKE. TARANAKI.
CONTROL VOLTAGE WIRING
BASIC EFFULENT
CONTROLLER
23 November 2021
Basic effulent control power wiring.PUB
PKZM0
T1 T2 T3
L1 L2 L3
PKZM0
T1 T2 T3
L1 L2 L3
DILM15-10
230V
T1 T2 T3
L1 L2 L3
A2
A1
DILM15-10
230V
T1 T2 T3
L1 L2 L3
A2
A1
TRUNKING
DOOR
K&N
OFF/ON
SWITCH
STIRRER
PUMP
MCB
(DOL)
STIRRER PUMP
ETE
24vdc
psu
STIRRER PUMP
(DOL)
Supply Earth /
Neutral
PUMP
MCB
(VSD)
L1 L2 L3
L1 L2 L3
PUMP
(VSD)
FUSE 3A
FUSE 3A
BREAKER
Finder
12.21
Time clock
BREAKER
CROUZET
MILLENNIUM 3
L N
Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8
I 1
I 2
I 3
I 4
I 5
I 6
I B
I C
I
D
I E I
F
I G
- -
Finder
83 .0 2
Tim e clo ck
GREEN
WASH
SS
L1 L2 L3
L1 L2 L3
GREEN
WASH
(SS)

CORKILL SYSTEMS LTD
5 TASMAN ST, OPUNAKE. TARANAKI.
CONTROL VOLTAGE WIRING
BASIC EFFULENT
CONTROLLER
20 January 2022
BASIC EFFULENT CONTROL VOL TAGE. PUB
PKZM0
T1 T2 T3
L1 L2 L3
PKZM0
T1 T2 T3
L1 L2 L3
I1 I2
DILM15-10
230V
T1 T2 T3
L1 L2 L3
A2
A1
DILM15-10
230V
T1 T2 T3
L1 L2 L3
A2
A1
Q1 Q2
FUSE 3A
FUSE 3A
24vdc
psu
Stirrer Pump
(DOL)
A
A
A
A
Cont
MCB
Green Pump
MCB
(soft start)
L1 L2 L3
FUSE 3A
Cont
MCB
IF
Fi nder
12.21
Time clock
Finder
83.02
Tim e clock
Q6
IE
To pot on
lid
Option
When
supplied with
no remote
10H
DE
Unused
4 2
4 3
4 4
4 6
4 7
4 5
4 8
4 1
4 0 4
9
OG OH IP IQ IR OJ
OF
5 0
IS
CROUZET
MILLENNIUM 3
PLC
L N
Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8
I
1
I 2
I 3
I
4
I
5
I 6
I
B
I
C
I
D
I
E I
F
I
G
- -
OF OG OH OJ OK OL
I
P
I
Q
I
R
I
S
I
T
I
U
I
V
I
V
Irrig
Pump
MCB
(VSD)
L1 L2 L3
A1 A2
C
NO
NC
FINDER 2 POLE
24VAC RELAY
OK
I3 Q5
I4
7 8 9 1
0
1 1
1 2 1
5
1 6
2 1
2 2
2 3
2 5
2 6
2 4
2 7
2 0
1 9
1 4
1 3 2
8
Q4 Q3 I5
1 8
QC
3/4
1 7
I6 IC ID Q6 Q7 Q8 IE IB
3 4 3
1
3 2
3 0
2 9
3 3 3
4
OL IU IV
1 2 5 6
IT To Relay

CORKILL SYSTEMS LTD
5 TASMAN ST, OPUNAKE. TARANAKI.
CONTROL VOLTAGE WIRING
BASIC EFFULENT
CONTROLLER
23 November 2021
BASIC EFFULENT CONTROL INPUT– OUTPUT.PUB
Stirrer
(DOL)
Pump
(DOL)
Pump
(VSD)
Remote Reset
Reset Indication
Remote Trip
4 2
4 3
4 4
4 6
4 7
4 5
4 8
4 1
4 0 4
9
OG OH IP IQ IR OJ OF
5 0
IS
Pump Indication
Common
Trip Indication
Start/Stop Stir
24v dc
Start/Stop Pump
Stir Indication
Outputs to
Harvest
Inputs from
Harvest
Power
VSD Running
9 1
0
1 1
1 2 1
5
1 6
VSD Start
Flow Fault
Flow meter powe r
To VSD To
Irrigator
Flow
VSD Reset
24v dc
1 4
1 3
1 7
1 8
Micro Therm
To Stirrer
24v dc
8 7
VSD 24 dc +
I3 Q5
I4
Q4 Q3 I5
QC
3/4
Reset
2 1
2 2
2 3 2
5
2 6
Pump Start/stop
Stirrer Start/Stop
Pump Status Lamp
Pump Timer return
24v dc
Stirrer Status Lamp
2 0
1 9
2 8
To remote
station
2 7
Stirrer Auto/ man
2 4
Pump Timer power
I6 IC ID Q7 Q8
Q6 IE IB
3 1
3 2
Flow Fault
Flow meter powe r
To
Green
Flow
24v dc
3 0
2 9
3 3
OL
IU
3 4
OV
To remote
Green pull
cord
Green Wash
Start/Stop
3 4
1 2 5 6
Soft start Running
Soft Start
Control Power 400v
24v +
Soft Start Go
To Green
Wash Soft
Start
To
Relay
To
Fuses
IT
Green Pump
(Soft Start)

CORKILL SYSTEMS LTD
2 King St, PO Box 16
OPUNAKE, TARANAKI. NEW ZEALAND
Ph [phone] Fax [phone]
CIRCUIT DIAGRAM FOR
AGFIRST
IRRIGATOR
CONTROLLER
January 31, 2022
AGFIRST-IRRIGATOR-WIRE.PUB
COPYRIGHT JUNE 2001 STEV E CORKI LL
12 13 18 19 27 29 32 33 20
DANFOSS TERMINALS
E
TRANSDUCER
06 05 04
RELAY 2
03 02 01
7 8 9 1
0
39 42 50 53 54 55
DANFOSS TERMINALS
RELAY 1
VSD Reset
24v dc
VSD 24 dc +
VSD Start VSD Running
To control
1
1
1
2
1
3
1
4

CORKILL SYSTEMS LTD
5 TASMAN ST, OPUNAKE. TARANAKI.
CONTROL VOLTAGE WIRING
BASIC EFFULENT
CONTROLLER
Kelco wiring for green wash
20 January 2022
BASIC EFFULENT KELCO.PUB
3 1
3 2
Flow Fault
Flow meter powe r
Main
Controller
24v dc
3 0
2 9
OL IU
a n
f
c no 1 2
nc no c
hd
Kelco E30
OL +24 -0
IU

CORKILL SYSTEMS LTD
5 TASMAN ST, OPUNAKE. TARANAKI.
CONTROL VOLTAGE WIRING
BASIC EFFULENT
CONTROLLER
Kelco wiring for irrigator
20 January 2022
BASIC EFFULENT KELCO.PUB
1 5
1 6
Flow Fault
Flow meter powe r
Main
Controller
24v dc
1 4
1 3
Q5 I4
a n
f
c no 1 2
nc no c
hd
Kelco E30
Q5 +24 -0
I4
To
Solenoid

CORKILL SYSTEMS LTD
5 TASMAN ST, OPUNAKE. TARANAKI.
CONTROL VOLTAGE WIRING
BASIC EFFULENT
CONTROLLER
Soft Start Wiring
20 January 2022
BASIC EFFULENT KELCO.PUB
3 4
1 2 5 6
Trip
Soft Start
Control Power 400v
Main
Controller
24v +
Soft Start Go
N
2
A
1
A
2
N
1
2 4
1 4
1 3
2 3
6 5
Soft Start
A
1
1 2 3 4 5 6

CORKILL SYSTEMS LTD
5 TASMAN ST, OPUNAKE. TARANAKI.
CONNECTION DIAGRAM
BASIC EFFULE NT CONTROLLER
Remote Control Station
23 November 2021
LAMP
N/O
LAMP
N/O
N/O
Pump Start/ Stop
Stirrer Start/ Stop
Stirrer Auto/ Manua l
24DC I6
IB
IC
Q7
Q8
N/O
ID
Reset
Reset
Pump Start/stop
Stirrer Start/Stop
Pump Status Lamp
Pump Timer return
24v dc
Stirrer Status Lamp
Main
Controller
Stirrer Auto/ man
Pump Timer power
I6 IC ID Q8 Q7 Q6 IE IB
Finder
83.0 2
Tim e clock
Q6
IE
Timer pot
Timer
24DC
2 1
2 2
2 3
2 5
2 6
2 0
1 9
2 8
2 7
2 4

CORKILL SYSTEMS LTD
5 TASMAN ST, OPUNAKE. TARANAKI.
CONNECTION DIAGRAM
BASIC EFFULENT CONTROLLER
LID WIRING WITH REMOTE
OPTION
23 November 2021
LAMP
N/O
LAMP
N/O
Pump Start/ Stop
Stirrer Start/ Stop
+ 24DC I6
IB
Q7
Q8
N/O
ID
Reset
Reset
2 1
2 2
2 3
2 5
2 6
Pump S tart/stop
Stirrer Start/Stop
Pump Status Lamp
Pump Timer return
24v dc
Stirrer Status Lamp
2 0
1 9
2 8
Main Controller
Connections
2 7
Stirrer Auto/ man
2 4
Pump Timer power
I6 IC ID Q7 Q8 Q6 IE
IB

CORKILL SYSTEMS LTD
5 TASMAN ST, OPUNAKE. TARANAKI.
CONNECTION DIAGRAM
BASIC EFFULENT CONTROLLER
Lid wiring without remote
23 November 2021
LAMP
N/O
LAMP
N/O
N/O
Pump Start/ Stop
Stirrer Start/ Stop
Stirrer Auto/ Manual
+ 24DC I6
IB
IC
Q7
Q8
N/O
ID
Reset
Timer pot
Timer
To Timer Z1, Z2
Reset
Pump Start/stop
Stirrer Start/Stop
Pump S tatus Lamp
Pump Timer return
24v dc
Stirrer Status Lamp
Main Controller
Connections
Stirrer Auto/ man
Pump Timer power
I6 IC ID Q7 Q8 Q6 IE IB
2 1
2 2
2 3
2 5
2 6
2 0
1 9
2 8
2 7
2 4