GTI Bailoy GTI-PM-004-1018-GB Installation instructions

GTI-PM-004-1018-GB
Hardware Guide
DESIGNERS AND MANUFACTURERS OF
For Golf, Sportsturf & Landscape applications
©Bailoy Products Limited

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Hardware Guide
Contents
Fixing the wall mounting brackets to the DOU.......................................................................................3
Fixing the DOU(s) to the wall..................................................................................................................3
DOU power supply..................................................................................................................................4
DOU storage warning..............................................................................................................................4
Fibre optic connection ............................................................................................................................5
CSG cables...............................................................................................................................................6
Cable ring-main...................................................................................................................................6
Surge Protectors .................................................................................................................................6
Solenoids.................................................................................................................................................6
Connecting the control cables to the DOU terminals.............................................................................7
Connecting the CSG cables .....................................................................................................................8
Trident CSG cable connections ...........................................................................................................8
Gemini CSG cable connections ...........................................................................................................8
Rain switch and alarms ...........................................................................................................................9
Rain switch input.................................................................................................................................9
Alarm inputs........................................................................................................................................9
Output voltage selection.........................................................................................................................9
Pump start relay....................................................................................................................................10
DOU indicators......................................................................................................................................10
Circuit breakers and fuses.....................................................................................................................11
Line (Surge) Protection Units................................................................................................................11
The Trident decoder..............................................................................................................................12
The Gemini decoder..............................................................................................................................13
Typical DOU configurations ..................................................................................................................14
Standard single DOU configuration ..................................................................................................14
Multiple DOU configuration..............................................................................................................14
DOU is remote from the PC ..............................................................................................................14
Distributed DOU configuration.........................................................................................................15
The Micro Board ...................................................................................................................................16
DIP switch settings................................................................................................................................17
DIP switch 1 to 4 ...............................................................................................................................17
DIP switch 5.......................................................................................................................................17
DIP switch 6.......................................................................................................................................17

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The Power Board...................................................................................................................................18
DTMF Receiver......................................................................................................................................20
Typical configurations.......................................................................................................................20
DTMF receiver using an internal radio module: ...............................................................................21
DTMF receiver using an external radio:............................................................................................21
Antenna installation..........................................................................................................................21
Communication Booster .......................................................................................................................22
Wiring diagram: ................................................................................................................................22

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Fixing the wall mounting brackets to the DOU
Each DOU weighs up to 26Kg (Depending upon the actual version) and is supplied with four steel wall
mounting brackets. Each bracket is pre-assembled with one M6 X 16mm set-screw, steel washer,
rubber washer, and expanding nut. Push the bracket assemblies into the four predrilled holes on the
rear of the enclosure and tighten the set screw such that the brackets are secured firmly to the
enclosure by means of the expanding nuts.
NOTE: It is important to ensure that the brackets are mounted vertically so as to protrude above and
below the top and bottom surfaces of the DOU (See Figure 1 and Figure 2).
Fixing the DOU(s) to the wall
The DOU(s) should be mounted to a flat vertical surface (e.g. brick wall) by means of the four mounting
brackets supplied. It is the Installer’s responsibility to ensure that the wall, or other vertical surface, is
of suitable material, flat and dry, and of sufficient strength to continuously and safely support the
mass of the DOU(s) to be installed.
For fixing to brick or concrete, the use of one of the following two options is recommended:
•Four off, M8 x 75mm (minimum) zinc plated expanding anchor bolts and nuts.
•Four off, 7.93mm x 62.5mm (minimum) zinc plated hex –head coach screws, together with
suitable plugs (e.g. “Rawl-plug”).
For mounting onto surfaces other than brick or concrete, it is the Installer’s responsibility to ensure
that any screws, bolts, or other fixings used are suitable for use with the base material, and of
sufficient size and strength to continuously and safely support the mass of the DOU(s) to be installed.
If a DOU is to be mounted onto a conductive metal surface, it is the Installer’s responsibility to ensure
that the mounting surface is properly earthed in accordance with the prevailing National and Local
electricity supply rules and regulations. If a DOU is to be mounted onto a surface consisting of wood
or other flammable material, it is the Installer’s responsibility to ensure that the installation is in full
compliance with National and Local building and fire prevention regulations.
Figure 1
Figure 2

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DOU power supply
Check the power supply tag to ensure correct incoming mains voltage before connecting the DOU This
tag is located near the bottom left corner of the power board and the supply voltage is also printed
on the DOU Serial Number Label. The mains supply input is internally protected by a 5A circuit breaker.
Always replace the metal terminal cover. The incoming mains supply must be capable of delivering 5-
amps continuously, and an external safety isolating device must also be provided as part of the
building installation.
The DOU must be permanently connected to a good quality earth for safety reasons and
for good surge protection. Use at least 2.5mm2(12 or 14 AWG) wire, or (preferably) 12mm
(1/2”) sleeved braiding to a grounded copper earth spike.
A DOU using a power plug must (additionally) remain connected to a permanent earth at
all times.
The standard DOU. enclosure is manufactured from painted mild steel and designed to be wall-
mounted inside a dry building, away from direct sunlight. The ambient temperature in which it
operates must lie within the range –5oC to +60oC (23oF to 140oF). Extra environmental protection must
be provided if the DOU is to be installed in an outdoor location.
WARNING: The DOU. mustbe installed in full compliance with the Local and National Electricity Supply
Authority Regulations, and only by competent and fully trained personnel. It is essential that the
installation and servicing procedures and instructions issued in this documentation be followed during
any installation and servicing of this equipment. The product must not be installed or serviced before
isolating all incoming mains voltage supplies elsewhere. The DOU. contains hazardous voltages.
All incoming cables must be protected from abrasion and must be relieved from mechanical strain
(cable glands are supplied with the DOU in order to help meet this requirement). If an incoming
(mains) power supply cable should slip its anchorage, placing a strain upon the individual conductors,
then the protective earth conductor must be the last to take the strain.
Any additional power cord anchorage required during installation must be made from insulating
material or must contain a lining made from insulating material. All unused cable entry holes in the
gland plate at the bottom of the DOU enclosure MUST be plugged with the special plastic bungs that
are fitted upon leaving the factory.
It is the Installer’s responsibility to ensure full compliance with the above two paragraphs.
See Also: The Power Board
DOU storage warning
Never put any items in the enclosure, it violates all Health & Safety rules.
You will have received a GTI Product folder when the system was commissioned. Items such as the
following, should be kept in the plastic wallet at the back of this folder.
•GTI installation CD
•Spare fuses
•Tool to adjust the potentiometers (Required for calibration)
•Spare cable crimps

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Fibre optic connection
Use Port 1 on the Micro Board (See page 16) to connect the fibre optic cable (FOC). Port 1 consists of
two sockets, match the colour of the plugs with the sockets as shown in the following diagram:
Figure 3
Legend for the above diagram:
Reference
Description
Bailoy part number
PC
Personal computer
GTI-PC-TW-ST
USB
One of the USB ports found on the PC
N/A
FOA
Fibre-optic adapter. This is a bidirectional converter, it
translates between electrical signals and light pulses that
can be transmitted through the FOC.
Do not put the FOA in the controller. That is
against all electrical design principles.
GTI-FOA
SPA
The USB<>Serial Port Adapter. Due to the requirements of
the FOA, it is highly recommended to order this device
from Bailoy to guarantee reliable operation.
This requires software, which is supplied
with the device, to be installed prior to
connection.
Furthermore, the Power Settings (Found in
the Windows Control Panel) of the
computer, must be reconfigured to ensure
the USB cannot enter standby mode.
GTI-USB-SPA
FOC
Fibre-optic cable. The cable consists of 2 fibres. Each fibre
is terminated with a grey plug on one side and a blue plug
on the other side. The cable also acts as an electric
insulator.
The cable is available in 3, 6 and 10m lengths. The
standard supplied length is 3m (GTI-FOC-3M).
GTI-FOC-3M
GTI-FOC-6M
GTI-FOC-10M
PORT1
This is the port to which the FOC connects. In the case of
a DOU, it is connected to PORT1, which can be found on
the Micro Board.
N/A
Use the FOA at the PC side (Again the colours must be matched as shown in Figure 3). Fibre optic Port
2 on the Micro Board is used to connect to the next DOU. Do not remove the rubber plugs from Port
2 unless the port is required to make the connection to another DOU.
Do not attempt to shorten the fibre optic cables as the terminations have been carefully polished.
Make a coil of the excess cable. The diameter of the coil must exceed 50mm (2”) to avoid damage to
the fibres.

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CSG cables
The maximum distance that a station can be located from the DOU is determined by the voltage
available at its decoder-terminals whilst the station is running. This in turn is decided by several
combining factors such as:
1. The current draw imposed by the station
2. The line voltage transmitted from the DOU
3. How many other stations are running simultaneously from the same CSG
4. The losses due to cable resistance (which clearly increase for running stations located at
greater distances from the DOU)
Stations that are located at long distances down the line will obviously be more affected by line
resistance than those that are located closer to the DOU.
A decoder should be located as close to its station solenoid as possible, ideally within 50 metres (55
yards).
For example, a Green has a single valve-in-head station located at each of its four corners. In this case,
one 4-way decoder controls all four stations as each station is within 50 metres. This saves on decoder
costs and connections.
Cable ring-main
Never create a “ring-main” in an attempt to reduce CSG volt drop problems, or to save cable size costs,
etc.
Surge Protectors
Surge Protectors may be attached at various intervals along the CSG cables in areas of high lightning
risk. They will help to protect the system from secondary surges but remember that surge protection
devices can fail in the event of an excessively heavy surge.
Solenoids
A good quality solenoid has a holding current of about 0.2A at 60Hz (Add 16% for 50Hz rating, 0.232A).
A much less efficient coil may require a current in excess of 0.5A at 24Vac. Power consumption details
can usually be found on the coil body.
Most solenoids are nominally rated at 24Vac but have a specified operating range of 19Vac to 30Vac
(In practice they typically work quite reliably down to about 17Vac).
The use of special “low current” solenoids appears to be an attractive proposition, because either
more stations can be run simultaneously, or a station canbe made up of a number of these low current
devices. However, these devices cannot be used in conjunction with DOU’s.

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Connecting the control cables to the DOU terminals
Never fold (solid) wires inside the DOU, or any other enclosure.
Most systems use control cables with solid copper wires which are more sensitive to breaks. Control
cables entering the DOU must be terminated using the “Pig tail” method, shown in figure 1 and not
the folded method shown in figure 2.
The shape of the “Pig tails” requires a longer length of wire which is more practical during fault finding
processes, especially when the technician wants to re-arrange wires.
The radius of the “pig tail” is made slightly larger than required. This helps to “push” the plug into the
terminal block on the power board.
Figure 1
Figure 2
By using the “Pig Tail” method, it is much easier to take current readings using a clamp
meter without disturbing the wiring.
Control cable
Cable gland
Each wire in the control cable shaped like a "pig tail"
CSG connector
Power board
Easy access for the multi-meter probe
DOU Enclosure
Control cable
Cable gland
CSG connector
Power board
Easy access for the multi-meter probe
DOU Enclosure

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Connecting the CSG cables
Trident CSG cable connections
The Trident terminal blocks J12 (CSG 1), J22 (CSG 2), J32 (CSG 3) and J42 (CSG 4) are used to connect
the course cables:
Course cable colours:
❶
Black
❷
Red
❸
Green
Gemini CSG cable connections
The COURSE terminal blocks J12 (CSG 1), J22 (CSG 2), J32 (CSG 3) and J42 (CSG 4) are used to connect
the CSG cables:
Course cable colours:
❶
Black
❷
Red
The optional backup controller (BC) is connected to the CTRL terminal blocks (J11, J21, J31 and J41).
Note that the polarity of these blocks is the opposite of the COURSE terminals.
Always connect all the terminals of J11, J21, J31 and J41 to earth when BC is not available.

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Rain switch and alarms
See Error! Reference source not found. section on page 18Error! Bookmark not defined. for the
location of connector J5. The inputs are internally connected to a 12Vac power source.
NEVER apply an external voltage source to any terminal of J5. Do not connect
inputs from different controllers together, observe strict isolation.
Special note for users of multiple DOU systems:
1.
NEVER make any interconnections between the Rain Switch (RSW) and alarm
inputs of different DOU’s
2.
If the Rain switch option is enabled, then GTI expects a rain switch to be
connected to each DOU You may opt to short the rain switch terminals in all
but one DOU
Rain switch input
The RSW input is closed in dry weather conditions. Wiring is not required unless the RSW option is
enabled in GTI (See the Rain switch input topic). A “Too wet” condition is signalled when one of the
rain switches opens.
❶
Common
❷
Rain switch
❸
Alarm input 1
❹
Alarm input 2
Alarm inputs
Each DOU has two additional alarm inputs. These inputs are designed to be operated from external
volt-free switches or relay contacts. An open-circuit input raises the alarm.
Wiring is not required unless the corresponding alarm input is enabled in GTI (See Alarm inputs topic).
❶
Common
❷
Rain switch
❸
Alarm input 1
❹
Alarm input 2
Alarm inputs
Output voltage selection
Each electrical zone (CSG) has a High/Low (H/L) switch, see The Power Board topic. Only use the 40Vac
(H) voltage setting in conjunction with Trident and Gemini decoders. These decoders regulate their
outputs, therefore extending the life expectancy of the solenoids and reducing the power
requirements (Read volt drop over the CSG cable).
Set the outputs to 40Vac (H), whenever possible, for best performance of the Gemini and
Trident systems.
H/L Switch position
CSG Output voltage
L
30Vac
H
40Vac

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Pump start relay
The DOU has a 1A / 240V rated pump start relay contact. The contact is normally open and closes:
1. For the duration of a watering cycle
2. When the Manual pump start option is used
It is the installer’s responsibility to ensure that the pump motor duty-cycles are not exceeded by
means of timers, PLCs, etc. Always replace the metal pump terminal cover.
See Also: The Power Board
DOU indicators
There are 6 indicators on the front panel of the DOU. From top to bottom these are:
Indicator
Description
POWER
Must be ON. It is a general indication that the micro board has a power supply
PWR OK
Must be ON. It is a general indication that the micro board has a power supply
SYNC
Normally flashing. Continuous ON or OFF indicates an error
PC MODE
ON when the DOU is in command.
:
•ON, the backup controller cannot be used
•OFF, the backup controller can be used to water
TRANSMIT
Normally off. Flashes when the DOU transmits data to the PC
RECEIVE
Normally off. Flashes when the DOU receives data from the PC

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Circuit breakers and fuses
The D.O.U. uses two circuit breakers and six 20mm glass cartridge, Anti-Surge type fuses:
Circuit breaker
Description
CB1
Protects the mains supply to all transformers. Value: 5A
CB2
Protects the 240V rated pump relay contact. Value: 1A
Fuse
Description
F1
CSG 1 over current protection. Value:
•Max. 3.15A at 30V CSG output
•Max. 2.50A at 40V CSG output
F2
CSG 2 over current protection. Value:
•Max. 3.15A at 30V CSG output
•Max. 2.50A at 40V CSG output
F3
CSG 3 over current protection. Value:
•Max. 3.15A at 30V CSG output
•Max. 2.50A at 40V CSG output
F4
CSG 4 over current protection. Value:
•Max. 3.15A at 30V CSG output
•Max. 2.50A at 40V CSG output
F5
Micro board power supply. Value: 500mA
F6
Auxiliary power supply. Value: 500mA
Downrate F1 to F4 to 2.5A when 40Vac output is selected in the corresponding
CSG. Failure to comply will cause irreversible damage to the DOU.
GTI monitors the status of fuses F1 to F4 and F6.
Line (Surge) Protection Units
The Line (Surge) Protection Units (LPU’s) can be replaced if they become damaged.
Under no circumstances should the controller be used without LPUs.
Be careful when replacing a LPU, it is possible to insert them incorrectly. Always isolate the incoming
mains supply before replacing a LPU. Refer to the Power Board section on page 18 to help locate the
LPU’s.
Trident and Gemini systems use different Line (Surge) Protection Units.

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The Trident decoder
Explanation:
❶
Manufacturing date
❷
Decoder type (1, 2, 3 or 4 decoder outputs)
❸
Write the programmed decoder numbers in the provided spaces with a permanent
water proof marker pen
❹
Hook to suspend the decoder in the valve box
All decoder outputs must be programmed prior to installation. See the Programming a
decoder chapter in the Setup Manual
Legend:
❶
CSG cable
❷
Solenoids
Wire
Colour
Wire
Colour
L
Red
B
Yellow
N
Black
C
White
S
Green
D
Orange
A
Violet
R
Brown

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The Gemini decoder
All decoder outputs must be programmed prior to installation.
See the Programming a decoder chapter in the Setup Manual
Legend:
❶
CSG cable
❷
Solenoids
The wire colours are as follows:
Wire
Colour
Wire
Colour
L
Red
C
White
N
Black
D
Orange
A
Violet
R
Brown
B
Yellow

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Typical DOU configurations
The symbols being used in the following sample configurations:
Item
Description
PC
The Personal Computer
C
The 9-way D-connector to fibre-optic converter
Port1, Port 2
The 2 fibre-optic ports on the Micro Board
F
Double fibre-optic cable. Supplied in lengths of max. 3 Meters
(10Ft)
CB
Communication Booster unit
P1, P2
The 2 fibre-optic ports of the Communication Booster
CC
The Communication Cable
12V
Each CB is supplied from a separate 12V (AC or DC) 250mA power
adaptor
Standard single DOU configuration
The DOU is local to the PC:
Multiple DOU configuration
Two or more DOU’s can be daisy-chained:
DOU is remote from the PC
You may have to use this configuration when retrofitting. When designing a new system consider
locating the DOU as close as possible to the stations it controls. Shorter CSG cables have the following
benefits:
1. Reduced labour and cable costs
2. Reduced potential volt-drop problems
3. Increased reliability
4. Maintenance and servicing becomes easier and therefore less expensive

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Distributed DOU configuration
This situation takes the previous sample a step further.
It is important to realise that each fibre-optic cable can be replaced by a pair of
Communication Boosters.
The range can be extended by using a pair of boosters as a repeater, provided that
a power source is available at the location of the repeater.
The example shows two DOU's that may be located at opposite ends of the site. Each DOU is located
close to the area it controls. More DOU's could be connected to DOU 1 or 2 (See example Multiple
DOU configuration above):

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The Micro Board
1
DIP-switches. See also DIP switch settings
2
Reset switch
3
A tag in the following format:
MODEL
: MMM-TTT-CC
SERIAL No.
: NNNNNN
DATE CODE
: MYY
Where:
•MMM is the model: TRI = Trident or GEM = Gemini
•TTT is the type: CEN = Central or EXP = Expansion
•CC is the number of CGS’s: 01, 02, 03 or 04
•NNNNNN is the DOU serial number
•MYY is the date code, where M is a reference to a calendar month and YY the year of
manufacturing
4
Fibre-optic Port 2. Connection to the next controller. The rubber plugs must be left in position when
the Port is not used
5
Fibre-optic port number 1. Connects to the PC
6
64 Way connector
7
Firmware chip. The details printed on this should ALWAYS match the details in ❸above

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DIP switch settings
The Micro Board has six DIP-switches. Push the switch lever down to switch ON. Push the switch lever
up to switch OFF. The ON positions are clearly marked on the housing.
DIP switch 1 to 4
The first four switches set the DOU number. The selected number must correspond to the number
given by GTI. All four switches must be set to the ON position for a single DOU system.
Under normal circumstances the new settings are not effective until the RESET switch on the Micro
Board has been pressed.
DOU number
Switch 1
Switch 2
Switch 3
Switch 4
1
❶
❶
❶
❶
2
⓿
❶
❶
❶
3
❶
⓿
❶
❶
4
⓿
⓿
❶
❶
5
❶
❶
⓿
❶
6
⓿
❶
⓿
❶
7
❶
⓿
⓿
❶
8
⓿
⓿
⓿
❶
9
❶
❶
❶
⓿
10
⓿
❶
❶
⓿
11
❶
⓿
❶
⓿
12
⓿
⓿
❶
⓿
13
❶
❶
⓿
⓿
14
⓿
❶
⓿
⓿
15
❶
⓿
⓿
⓿
16
⓿
⓿
⓿
⓿
⓿
Off
❶
On
DIP switch 5
This switch must be set to correspond with the mains frequency. Some of the DOU’s timing depends
on the correct setting:
Switch 5
Frequency
OFF
50Hz
ON
60Hz
DIP switch 6
This switch sets the way the DOU handles the hardware reset:
Switch 6
Calibrate
OFF
Calibrate on reset. This is the default setting
ON
Do not calibrate on reset

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The Power Board
1
Mains supply input. Check the tag ❷before installing the DOU:
•L = Live conductor input (Hot)
•E = Earth
•N = Neutral conductor input
2
A tag in the following format:
MODEL
: MMM-TTT-CC
SERIAL No.
: NNNNNN
DATE CODE
: MYY
Where:
•MMM is the model: TRI = Trident or GEM = Gemini
•TTT is the type: CEN = Central or EXP = Expansion
•CC is the number of CGS’s: 01, 02, 03 or 04
•NNNNNN is the DOU serial number
•MYY is the date code, where M is a reference to a calendar month and YY the year of
manufacturing
3
Mains supply circuit breaker
4
Rain switch and alarm inputs
5
Decoder programmer pin header, connects to the front panel
6
The Course wiring terminals. See the Connecting the CSG cables topic
7
Pump start circuit breaker
8
Pump start contact (Max. 1A/240Vac)

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Check the power supply tag (❷) to ensure correct incoming mains voltage before connecting the
DOU.
This tag is located near the bottom left corner of the power board and the supply voltage is also
printed on the DOU serial number label. The mains supply input is internally protected by a 5A circuit
breaker (❸). Always replace the metal terminal cover.
The incoming mains supply must be capable of delivering 5A continuously, and an external safety
isolating device must be provided as part of the building installation.
The DOU must be permanently connected to a good quality earth for safety reasons and for good
surge protection. Use at least 2.5mm2 (12 or 14 AWG) wire, or (preferably) 12mm (1/2”) sleeved
braiding to a grounded copper earth spike.
A DOU using a power plug must (additionally) remain connected to a permanent earth at all times.
The standard DOU enclosure is manufactured from painted mild steel and designed to be wall-
mounted inside a dry building, away from direct sunlight. The ambient temperature in which it
operates must lie within the range -5oC to +60oC (23oF to 140oF). Extra environmental protection must
be provided if the DOU is to be installed in an outdoor location.
WARNING: The DOU must be installed in full compliance with the Local and National Electricity Supply
Authority Regulations, and only by competent and fully trained personnel. It is essential that the
installation and servicing procedures and instructions issued in this documentation be followed during
any installation and servicing of this equipment. The product must not be installed or serviced before
isolating all incoming mains voltage supplies elsewhere. The DOU contains hazardous voltages.
All incoming cables must be protected from abrasion and must be relieved from mechanical strain
(cable glands are supplied with the DOU in order to help meet this requirement). If an incoming
(mains) power supply cable should slip its anchorage, placing a strain upon the individual conductors,
then the protective earth conductor must be the last to take the strain. Any additional power cord
anchorage required during installation must be made from insulating material or must contain a lining
made from insulating material. All unused cable entry holes in the gland plate at the bottom of the
DOU enclosureMUST be plugged with thespecial plastic bungs that are fitted upon leaving the factory.
It is the Installer’s responsibility to ensure full compliance with the above two
paragraphs.