Galcon GalStar User manual

GalStar
Instruction 1.0

3
GalStar Instruction 1.0
Index
1) Preface ............................................................................................................................................... 6
2) Tutorial ............................................................................................................................................... 10
2.2. Setting system to active .............................................................................................................. 10
2.2.1. Main menu ........................................................................................................................ 10
2.2.2. Accessing tech. setup ....................................................................................................... 11
2.2.3. System setup .................................................................................................................... 11
2.2.4. Setting system to active .................................................................................................. 12
2.3. Defining the input/output ........................................................................................................... 12
2.3.1. Setting the output of valve No. 1 ..................................................................................... 12
2.3.2. Setting the Fertilizer pump output ................................................................................... 13
2.3.3. Setting the Fertilizer pump input ..................................................................................... 14
2.4. Setting the irrigation head active ................................................................................................. 14
2.5. Setting the valve ....................................................................................................................... 15
2.6. Setting the Fertilizer constants ................................................................................................. 16
2.6.4. Fert. Programs ................................................................................................................ 17
2.7. Program Constants ................................................................................................................... 18
2.8. Program programming ............................................................................................................. 19
2.9. Starting the Program ................................................................................................................. 19
3) Basic Operation ............................................................................................................................... 20
3.1. The main menu ......................................................................................................................... 20
3.2. Operation of head No. 1 ........................................................................................................... 21
3.3. Programs and Sequences ........................................................................................................ 22
3.4. Program programming ............................................................................................................. 23
3.5. Program constants .................................................................................................................... 25
3.6. Sequence .................................................................................................................................. 27
3.1.1. Sequence programming .................................................................................................. 27
3.1.2. Sequence constants ....................................................................................................... 28
3.7. Fertiliation ................................................................................................................................. 29
4) Advanced Operation ....................................................................................................................... 32
Irrigation program ........................................................................................................................... 32
• Program information ..................................................................................................................... 32
• Irrigation program programming ................................................................................................... 33
• Program constants ....................................................................................................................... 33
• Sequence status .......................................................................................................................... 35
o Sequence data .......................................................................................................................... 35
• Program Faults ............................................................................................................................. 36
• Manuel overriding ......................................................................................................................... 36
Valve status ..................................................................................................................................... 37
• Last Irrigation ................................................................................................................................ 37
• Valves daily .................................................................................................................................. 37
• Valves constants .......................................................................................................................... 38
• Valves Group ................................................................................................................................ 39
• Valve accumulation ...................................................................................................................... 40
• Valves faults ................................................................................................................................. 41
• Valves manual .............................................................................................................................. 41

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GalStar Instruction 1.0
Fertilization ...................................................................................................................................... 41
EC/PH Control .................................................................................................................................. 41
• Fertilizing status ............................................................................................................................ 42
o Fertilizing programs ................................................................................................................... 43
o Fertilizer pump status ................................................................................................................ 44
• Fertilizer pump setup ............................................................................................................ 45
o Fertilizer center constant ........................................................................................................... 46
o EC/pH constants ....................................................................................................................... 47
• EC/pH Faults ................................................................................................................................ 47
Head alarms ..................................................................................................................................... 48
Head constants ................................................................................................................................ 48
Valve/line order ................................................................................................................................ 50
Pause elements ............................................................................................................................... 51
Manual opening time ...................................................................................................................... 52
Head Faults setup ........................................................................................................................... 52
• Filter Flush status .......................................................................................................................... 52
• Filter flush program ....................................................................................................................... 54
• Filter flush setup ............................................................................................................................ 54
Water counter status ....................................................................................................................... 56
• Water counter setup ...................................................................................................................... 56
Head 2 ............................................................................................................................................... 56
System status .................................................................................................................................. 57
• Head 1 Program status ................................................................................................................. 57
• Sequences status .......................................................................................................................... 58
• Valves status ................................................................................................................................. 58
• Fertilizers status ............................................................................................................................ 59
• Head 2 Status ............................................................................................................................... 59
• Other elements status ................................................................................................................... 59
• Auxiliary status .............................................................................................................................. 59
• Control sensor values ................................................................................................................... 59
• Conditioned inputs ........................................................................................................................ 59
• General counters status ................................................................................................................ 59
• Logic condition status .................................................................................................................. 59
General elements ............................................................................................................................ 60
• Aux. output .................................................................................................................................... 60
• Auxiliary program .......................................................................................................................... 61
• Auxiliary queue ............................................................................................................................. 62
• Manual Auxiliaries ......................................................................................................................... 62
Logic Conditions ............................................................................................................................. 62
• Logic conditions status .................................................................................................................. 62
• Logic condition programming ........................................................................................................ 63
• Condition definitions ...................................................................................................................... 63
Diaries and Alarms .......................................................................................................................... 65
• Alarms status ................................................................................................................................ 65
• Alarms timing definition ................................................................................................................. 65
Index

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GalStar Instruction 1.0
• Event logs viewer ......................................................................................................................... 66
• Alarm log ...................................................................................................................................... 66
• View diary ..................................................................................................................................... 66
• Alarms auto canceling ................................................................................................................. 66
• Reset Diaries ................................................................................................................................ 66
• Logs massage setup .................................................................................................................... 67
• Double outputs info ....................................................................................................................... 67
Manuel overriding ........................................................................................................................... 67
• Manual head 1 .............................................................................................................................. 67
• Manual programs .......................................................................................................................... 68
• Manual sequence ........................................................................................................................ 68
• Manual valves ............................................................................................................................... 68
• Manual flushing ............................................................................................................................ 68
• Manual auxiliary outputs .............................................................................................................. 69
Pause ............................................................................................................................................... 69
5) Hardware Setup Instructions .......................................................................................................... 70
General specifications ................................................................................................................... 70
1. Gal-Star's Casing ........................................................................................................................ 71
2. Display and keyboard ................................................................................................................. 74
3. CPU Board .................................................................................................................................. 75
4. AC Power Supply ........................................................................................................................ 76
5. AC Outputs Card ......................................................................................................................... 78
6. Discrete Inputs Card .................................................................................................................. 80
7. AC Analog inputs Card ............................................................................................................... 81
8. DC Power Supply ........................................................................................................................ 83
9. DC Outputs Card ........................................................................................................................ 84
10. DC Analog Inputs Card ............................................................................................................. 86
Gal-Star Mini .................................................................................................................................... 87
1. Mini Gal-star AC Card ................................................................................................................. 88
2. Mini Gal-Star DC Card ................................................................................................................ 89
6) Software Setup Instructions ............................................................................................................ 90
1. Technical Menus ......................................................................................................................... 90
2. System Setup .............................................................................................................................. 90
3. Time Setup .................................................................................................................................. 91
4. Communication setup ................................................................................................................. 91
5. Total initiation .............................................................................................................................. 93
6. I/O connection ............................................................................................................................. 93
7. Connection wizard ...................................................................................................................... 95
8. Test hardware ............................................................................................................................. 96
9. Sensors ....................................................................................................................................... 96
10. Metrological info ..................................................................................................................... 102
7) Gal-Star PC Operation .................................................................................................................. 104
1. General Programming ............................................................................................................... 104
2. Programming the fert program .................................................................................................. 104
3. Programming the irrigation program ......................................................................................... 106
Index

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GalStar Instruction 1.0
The Layout of the Manual: The manual is set out in an order that goes from the simple to the
complex. It starts off with general knowledge for the operator; the next “Tutorial” chapter is designed for
capable operators who can follow basic examples in order to learn how to operate the controller. The
“Basic Operation” chapter describes the most important functions. The “Advanced Operation” chapter
describes the rest of the controller’s functions. This chapter is designed for system installers and
advanced operators. The “Setup” chapter is designed for system installers only. The “PC Operation”
chapter describes how to use the PC controller software.
General Description: The newly designed Gal-Star controller is a medium sized modular controller
with up to 32 outputs and 24 inputs (combination of analog and discrete inputs). There are two models:
AC and DC. It comes in two different casings (standard and large). Although the Gal-Star controller
can be connected to a PC computer it is mainly designed to be locally operated via the keyboard and
display. Because of its unique function keys it represents a breakthrough in user friendliness in controller
operation. Its components are of the most advanced type to be found in the market. The controller is
designed for outdoor installation and complies with outdoor specifications.
Unique Features:
• Wide screen display of 15 rows.
• Switched AC power supply working in the range of 100-240 volts, 50-60 Hz.
• Output through relays (for higher protection).
• Integral add-on protection units (for outputs, inputs and analogs.
Software:
The Gal-Star can be defined to work with up to:
• 2 irrigation heads each containing:
o Up to 32 valves
o 1 Main valve
o 3 Fertilizer Pumps And Meters
o 4 Water Meters
o 4 Filter Flushing Stations
o 1 Pressure Sustaining Valve
• Sensors:
o Up to 8 Direct Sensors
o Up to 10 Communication Sensors
o Up to 10 Non-Linear Sensors
o Up to 4 Sensor Groups
o Full Meteorological Setup
• Up to 4 Auxiliary Outputs
• 1 Alarm Output
• 8 Conditioned Inputs
• 4 General Counters
1. Preface

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GalStar Instruction 1.0
Operating The Controller Via The Keyboard And Display
Screen Layout:
When the controller is connected to the power supply, the screen is usually off (for power conservation)
touching any of the keys turns the screen on. The top row of the screen always shows the title of the
screen in capital letters. The next row (between 2 lines) displays the number of the head, the type and
number of the element and the screen number for quick access. The main area of the screen shows
varying parameters for information and programming. On the two sides of the screen the titles of the
function keys are located; they alter in accordance with the specific screen displayed. Details of the
current time and date are displayed on the bottom row.
Keyboard Layout:
The keyboard contains 10 digit keys, a decimal point, clear, 13 navigation keys and 8 function keys.
The key clears the parameter below the cursor.
Navigation:
In order to navigate the Gal-Star menus use the function and navigation keys to access the required
screens.
• Function Keys: The “Function Keys” access specific locations. The function of the key alters
according to the current screen.
• Element Screen: There are two different types of screens: “Element Screens” and “Non-
Element Screens”. “Element Screens” are screens that apply to many elements of the same
type, for example: “Program Programming” and “Valve Setup”. “Non-Element Screens” are all
other screens.
• Navigation keys:
Return to the “Main Screen”.
Go back one screen, exit from editing without changing data. Note: when pressing “Esc”
after editing you will be prompted to press “Enter” to confirm the changes.
1. Preface

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GalStar Instruction 1.0
• In an "Element Screen" jumps to a specific element number (similar to “Next/
Prev”). Upon pressing “jump” the message “Jump to element __” appears, enter
the element number and press “Enter”.
• In a "Non-Element screen" jumps to a specific address (screen). Upon pressing
“jump” the message “Jump to screen __” appears, enter the direct screen number
and press “Enter”.
Select an option from alpha numeric parameters.
and scroll the screen when the number of display parameters exceeds 12 rows.
and change the number of the element in a designated screen. For example: when entering
“Program programming” you will always access “Program No. 1”. In order to go to program No. 2
press “Next”. In order to return to “program No. 1” press “Prev”. Please remember that "jump" takes
you directly to the required element number.
Arrows moves the cursor in programmable screens.
confirms parameter changes, confirms actions when required.
Editing:
Upon accessing a screen containing programmable data the cursor is above the first programmable data.
Use the arrow keys to navigate between data – the cursor moves accordingly. To change parameters:
type the required numeric value or press ”Select” to choose from the alpha numeric options (while the
cursor is on the parameter). Confirm the change by pressing “Enter”. When you have finished editing
all of the parameters on the screen press “Esc” and then “Enter” to confirm the changes.
Examples: The following examples show how to navigate and edit.
In order to enter the parameter “Water Required” in Irrigation Program No.5:
Step 1: Press the function key “Head 1” in the “Main Screen” to access the “Head 1 Status” screen (1).
Step 2: Press the function key “Prgrm Sequnc” (Programs Sequences) to access the “Irrigation
Program” screen (12).
Step 3: Press the function key “Prgrms Prog.” (Program Programming) to access the “Irrigation
Program” screen (122) program No.1.
Note: Instead of carrying out steps No. 1 – 3 you can simply press “Jump” and enter the direct
access no. (122) and then press “Enter” to directly access the “Irrigation Program”.
Step 4: Press “Next” 4 times to access program No.5 or press “Jump” and type the number of the
required program (in this example – 5) and then “Enter”
1. Preface

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GalStar Instruction 1.0
1. Preface
Step 5: Since the cursor is above “Water Required”, enter the quantity (according to the unit set)
and then press “Enter”
In order to program “Day Timing *” (alpha numeric parameter) carry out the following steps:
Step 6: Press “Page Down” to scroll the screen.
Step 7: Press “Down” 5 times to reach the required parameter.
Step 8: Press “Select” to choose one of the options (“Cyclic”, “Weekly”).
Step 9: Press “Enter” to confirm.
Step 10: Press “Esc” the message “Are you sure? ENTER to accept, ESC to reject” appears.

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GalStar Instruction 1.0
The tutorial chapter is designed to provide an operation guideline for operators with advanced
controller skills who have not as yet operated this Gal-Star controller. Operators requiring further
assistance should refer to the “Operation Chapter” that provides a detailed description of all of the
controller functions.
The tutorial does not explain the hardware set up.
In this tutorial we will explain how to set up an irrigation valve, its water counter and fertilizer pump and
start the irrigation. We highly recommend going over the tutorial before the controller is connected.
2.1 The required steps are:
2.1.1 Setting system to active.
2.1.2 Defining I/O.
2.1.3 Setting the irrigation head to active.
2.1.4 Setting the valve.
2.1.5 Setting the fertilizer pump.
2.1.6 Program constants.
2.1.7 Program programming.
2.1.8 Start Program.
2.2 Setting System to Active: The first step requires the following stages:
2.2.1 Main Menu (0): The starting point for any programming process is the “Main Menu”. In
order to access the “Main Menu” press the “Main” key.
The “Main Menu” is also automatically accessed: when the controller is turned on or
when the keys are not touched for half an hour.
2. Tutorial

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GalStar Instruction 1.0
2. Tutorial
2.2.2 Accessing Tech. Setup (6): Press the “Tech. Setup” “function key”, the word
“password” flashes on the bottom part of the screen. Enter to
access the technical menus.
2.2.3 System Setup (61): Press the “System Setup” “function key” to access the “System
Setup” screen.
Press
select

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GalStar Instruction 1.0
2. Tutorial
2.2.4 Setting System to Active: Press the “Select” key to change the parameter “System
Setup” from “N.Active” to “Active” then press “Enter”. Press “Esc” and then “Enter” to
confirm the changes. You will return to the “Technical Menu” screen.
2.3 Defining the Input/Output (62): In the “Technical Menu” screen press the “IO Concts” “function
key” to access the “I/O Connection” screen in which the I/O cards installed are shown. Then
press the “Head 1 Conn” “function key” to access the “Head 1 Connections” screen (621).
2.3.1 Setting the Output of Valve No. 1 (6214):
Press the “Valves” “function key”.
In the above “Valve Connections” screen, assign: “Slot number 2” / “Port number 1” to
valve number 1 (the numbers are according to the example shown but obviously you
must enter the number of the slot according to the location of the output card in your
controller hardware setup). Press “esc” and confirm by pressing “enter”.
set

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GalStar Instruction 1.0
2. Tutorial
2.3.2 Setting the Input for Water Counter No. 1:
Press the “Water Cntrs” “function key” in the “Head 1 Connections” screen to access the
“Head 1 Input” screen.
In the above “Head 1 Input” screen (6215) assign slot number 1/ port number 1 (1/001)
to counter no. 1. and set the pulse size for counter no. 1.
An example of programming the parameter:
Press:
Press and confirm by pressing
2.3.3 Setting the Fertilizer Pump Output:
In the “Head 1 Connection” screen press “Fert Pumps” to access (6212):
In the above “F.Pump Out Connect” screen assign slot number 2/ port number 2 (2/002)
to “Fertilizer Pump” No. 1.

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GalStar Instruction 1.0
2. Tutorial
2.3.4 Setting the Fertilizer Pump Input: In the “Head 1 Connection” screen, press “Fert.
Cntrs.” (fertilizer counters) to access 6216):
Set the slot and port to 1/002 and the size of the pulse for fertilizer counter No. 1 to
1.000. See the above example for the “Water Meter Setup”.
2.4 Setting the Irrigation Head to Active:
Press the “Head 1” “function key” in the “Main menu” screen to access:
"In the above screen (1) the status of the irrigation head is shown. Press on the "Head
Consts" function key to access (16):
Press “Select” to change the “Operation Setup” parameter to “Automat” and then press “Enter”.
Press “esc” and confirm by pressing “enter”.
Change
press

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GalStar Instruction 1.0
2. Tutorial
2.5 Setting the Valve:
In the “head 1 Status” screen press the “Valves” (13) “function key” to access:
Press the “Valve Const” “function key” to access (133):
2.5.1 Set the “Valve setup” parameter to “Active”.
2.5.2 The “Valve type” parameter must be “Irrigat”.
2.5.3 Set the “Water Meter No.” to “1”.
Press “Esc” and confirm by pressing “Enter”.
2.6 Setting the Fertilizer Constants:
2.6.1 Press “Fert” in the “Head 1 Status” screen to access (14):
Press

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GalStar Instruction 1.0
2. Tutorial
2.6.2 Press the “Fert. Pumps” and then “F.Pumps Const.” “function key” to access (1423):
• Select “By Puls” for “Fert.Pump Type”. Press Esc. and confirm by Enter.
• Press "Esc" to access the “Fertilizing Status” screen.
• Press the “F.Cntr Consts” (fertilizer center) "function key" in the “Fertilizing Status”
screen to access (143):
Press

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GalStar Instruction 1.0
2. Tutorial
2.6.3 Select “Active” for the “Operation Setup” parameter.
Press “esc” and confirm by pressing “enter”. You will return to the “Fertilizer Status”
screen. The fertilizer status should be “Ready”.
2.6.4 Fert Programs:
In the “Fertilizer Status” screen press the “Fert.Prgms” “function key” to access (141):
2.6.4.1 Select “Mins:Secs” for the “Fert.Unit” parameter and “5” for the “Fert Quant. Pmp A”.
Press “esc” and confirm by pressing “enter”.

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GalStar Instruction 1.0
2.7 Program Constants:
2.7.1 Press “Main Menu”>“Head1”>”Prgrms Sequnc” to access (12):
2.7.2 Press “Prgrms Consts” to access (123):
2.7.2.1 Press the “down” key once to reach “Program Setup”, select “Active”.
2.7.2.2 Change the “Water Unit” parameter to “Min:Sec”.
2.7.2.3 Set the first valve of the program to No. 1. Press “Enter”.
Press “esc” and confirm by pressing “enter”. You will return to the “Irrigation
Program” screen in which the “program status” parameter should be “Strt Tim” (i.e
there is no start time defined) (please note: this can take up to a minute).
2. Tutorial
press

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GalStar Instruction 1.0
2. Tutorial
2.8 Program Programming:
In the “Irrigation Program” screen press the “Prgrs Prog.” function key to access (122):
2.8.1 Set the “Wtr. Req.” (water required) parameter to “10.00” minutes.
2.8.2 Press the “Down” key to reach “Fert Prog No.” and set it to “1”.
Press “esc” and confirm by pressing “enter”.
2.9 Starting the Program (7):
In the “Main Menu” press the “Manual”>”Manual Head 1” function keys to access (71):
Change the “Start Program No.” parameter to “1” and press “Enter” (note: after a few seconds
the parameter returns to zero). Press the “Main” key to return to the “Main Menu” and confirm
that “Head No. 1” is “fertigating” and that “Valve No.01” is operating. (After a while water and
fertilizer pulse faults will appear).
This chapter explains the most important and frequently used functions and how to use them. The
rest of the operations are described in the “Advanced Operation” chapter.
Change to 1

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GalStar Instruction 1.0
3. Basic Operation
3.1 The Main Menu Screen: This is the first screen to appear and is used as the base for all
screen navigation.
When the controller is switched on or left untouched for more than half an hour the current
screen will be the main menu screen (0).
Screen explanation: (information screen only, cannot be edited)
•System Status: Shows the status of the system, the options are: N.Active, Active,
Irrigating, Paused, Alarm.
• Head Status: The table shows the status and the numbers of valves operating in each of
the two heads. Each head is displayed in a separate column. The status options are: N.Active,
Valves, Ready, Pause, Irrigat (irrigating), Fertig. (irrigation with fertilizer), Alarm.
• Navigation: From the “Main Menu” it is possible: to access “Head 1” or “Head 2”, to see
the “System Status”, “General Elements”, “Diary and Alarms”, to enter (with password) the
“Technical Setup”, to enter “Manual Overriding” and to “Pause” the system.