Control Room SOP

Version 1.0
TOC:
Control room checklist
Control room map
Pumps
- Pump maintenance
Chemical mixer
- Recommendation on the chemical mixing system
- Wash
- Drain
- Solution transfer
- Fertilizer rates table
- Refill fertilizer tank
Fertilizer tanks
- Wash
- Drain
Electrical
- Electrical cabinet
Irrigation controller:
- Overview
- Power On/Off
- Irrigation controller manual operation
- System alarms and troubleshooting guide
Fertilizer table
- Calibration
Filters
- Manual filter flushing
- Check filter flushing accumulations
Main irrigation valves manual operation
Irrigation backup infrastructure
Electrical failures

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Control room checklist
Control room checklist should be performed weekly at the beginning of the week.
This checklist aims to early identify emerging malfunctions.
In order to monitor system operation thoroughly, all inspections and parameters should
be recorded on a dedicated sheet.
 Check pumps:
 Visual inspection – check for noise, vibrations, leakage, overheat and
damages in the engine and the pump's body.
 Check ampere meter for differences between the original current (nominal)
and the present current with the same working conditions (same flowrate).
 Check output pressure – the standard pressure should indicate 4 bars.
Record the output pressure.
 Check fertilizer tanks quantities are more than 2500 in fertilizer tank #1 and #2. If
the tanks need to be filled – go to Refill fertilizer tank procedure.
 Verify the chemical mixer is empty and clean using its inspection door (Fig. 1).
 Check for leakage within the control room. Check pipes, fittings, valves and floor.
 Verify proper operation of the irrigation controller. Check for status and alarms.
 Verify the filters has been cleaned according to cleaning protocol.
 Clean all manual cleaning filters (fertilizer tanks output filters, solution transfer filter
- Fig. 2).
 Check fertilizer tables for damages and leakages.
 Check main irrigation valves in correct position – open field and plantation in AUTO,
greenhouse in OPEN with fertilizer table pump in 'A' (Fig. 3).
 Check water level in the pond (Fig. 4).
 Verify no distinctive odor or color is sensed, no large growth of algae (algal bloom) in
the pond.

Report to maintenance personnel if repair is needed.

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 Inspection
door

Fig. 1 – Chemical mixer inspection door

Solution
transfer filter

Fertilizer
filter

Fig. 2 – Manual cleaning filters

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 Greenhouse
fertilizer table
pump switch

Fig. 3 – Greenhouse fertilizer table pump switch

Fig. 4 – Water level meters in the pond

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Control room map

Fertilizers
and
Fertilizer tanks area
chemical
mixer
room

Pumps
Main control room
room

Fig. 5 – complex top view

Fig. 6 – complex overview

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 Fig. 7 – complex overview (transparent walls)

The control room comprises a complex of 4 areas – fertilizers tanks area, fertilizer and
chemical mixer room, pumps room and main control room.
The complex objectives are as follows:
- Pump the water from the pond at the required pressure and quality.
- Maintain fertilizer containers filled with sufficient solution by using the chemical
mixer for field operation.
- Provide fresh water for nursery, germination and additional usage (mixer, cleaning,
etc.).
- Provide precision controlled real-time water-fertilizer rates for field fertigation (open
fields, plantations and greenhouses).

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 Pumps
Pump operation is automatic and provide an adequate continuous pressure for the
irrigation system and service water ports. A pressure of 4 bars should be maintain
throughout the operation of all water consumption scenarios.

25 Ha pumps

5 Ha pumps

Fig. 8 – Pumps room

Pump maintenance
- Preventative maintenance is the recommended method of maintenance.
- Manufacturer recommendations – maintenance is based on regular and periodical
treatment according to a treatment table established by the user in accordance with
the recommendations of the manufacturer.
- Logbook - the maintenance should be made by the book - a logbook for
maintenance and treatment should be kept in which the failures of various
accessories are noted, their solution and the treatment given in various dates.

All maintenance operation should follow manufacturer guide instructions and

recommendations. The following procedure is general method for pump maintenance.

Equipment:
- Tools
- Spare parts

Procedure
- Inspection of performances:

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 o Visual inspection – check for noise, vibrations, leakage and damages in the
engine and the pump's body.
o Electric current inspection – check the ampere meter for differences
between the original current (nominal) and the present current with the
same working conditions (with the same flowrate).
o Pressure inspection at the output of the pump – check for decrease in water
pressure (at the same flowrate) during a period of time.
Any substantial deviation from the values of the nominal data requires a shut-down
of the pump and finding the reason for the difference.
- CAUTION: Operation of a "dry pump" is prohibited at all times.
- Greasing of bearings - the axle bearings should be oiled or greased according to the
manufacturer's instructions.

Chemical mixer
The chemical mixer purpose is to mix and melt fertilizers together at the correct rate
with water dilution so the fertilizer solution would be ready at the tank to be pumped to
the water system and further to the field.
The mixer is a 600 liters tank with a pump for transferring the solution from the mixer to
each tank.
After the mixer output there is a filter and a 4-way distribution manifold to choose
which tank is to be filled.
Amounts and rates for each tank are placarded on a sticker and on a sign near the mixer
– go to Fertilizer rates table.

Recommendation on the chemical mixing system

The priority is for a small mixing tank (600 liters) to dissolve the fertilizer and the
accuracy of the concentrates. The dissolved material is then transferred with a pump to
the required 5 cubic meter tank. Under the weather conditions in Indonesia the tank can
be a tank without an inner mixer.

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 Pump operation
switch

Dissolving
valve (#2) Water input
valve (#1)

Drain valve
Mixer pump

Fig. 9 – Chemical mixer

Wash chemical mixer
Mixer cleaning is an option. Due to very high dilution of the solution residues it is not
necessarily needed to clean the mixer.
Mixer cleaning is required after dissolving chemicals (pesticide, herbicide, etc.).

Procedure:
1. Rotate the water input valve to the open position (Fig. 9).
2. Drain valve can be switched to fully open position or closed position according to the
washing operation (Fig. 9).
3. When finish – close the water input valve.
4. Drain the mixer – go to Drain procedure.

Drain chemical mixer

Drain line of the chemical mixer is connected to the draining line of all other fertilizer
tanks.

Procedure:
1. Verify the solution within the mixer require draining.
2. Rotate the drain valve to the open position (Fig. 9).
3. When mixer is empty – rotate the drain valve to the close position.

Solution transfer
Solution transfer comprises of:
- Mixer pump mounted at the bottom of the chemical mixer.
- Solution output valve.
- Solution transfer filter.
- Distribution manifold with 4 valves.
- Solution pipelines from the manifold to each tank.
- Tank solution input valves for each tank.

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 Solution Distribution
transfer filter manifold
valves
Tank solution
input valve

Distribution
manifold

Fig. 10 – Distribution manifold

Fertilizer rates table

Amounts for Amounts for
100 liters 600 liters
Mixer (0.6 cube) 100 Liter water 600 Liter water Product
Tank 1 (5 Cube) Kg Kg
Potassium nitrate (KNO3) 11.8 70.8 PN Crystal
Monoammonium phosphate (M.A.P) 3.3 19.8 ULTRADAP
Micro Mix 0.27 1.62 Meroke VITAFLEX
Tank 2 (5 Cube)
Calcium nitrate (CaNO3) 10 60 Calnit
Magnesium nitrate (MgNO3) 10 60 MgNO - Magnit

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Refill fertilizer tank using the chemical mixer:
Refill for the fertilizer tanks is performed using the chemical mixer and the solution
transfer assembly.
If small amounts are needed (less than 200 liters) – go to Refill fertilizer tank in small
amounts procedure.
Solution transfer filter should be opened and cleaned once a week.

Equipment
- Protective mask and goggles
- Fertilizers/chemicals
- Fertilizers rate table

Procedure
1. Decide which tank to fill and verify all the valves are set to Off.
2. Check the relevant tank and verify that there is enough volume to fill 600 liters (this
is the amount to be filled by the chemical mixer).
3. Check the amounts of required fertilizers and verify no lack of materials (see
Fertilizer rates table).
4. Verify the mixer is clean or the remaining solution is equivalent to the required one.
5. NOTE: Always fill the mixer with water before adding fertilizers.
6. CAUTION: Use protective mask when operating the chemical mixer.

Solution preparation:
7. Rotate the blender operation switch to On (Fig. 13). The blender should stay in the
On position until the end of this procedure.
8. Fill the mixer with 200 liters of water by rotating the water input valve (#1) to the
open position. Close the valve when it reaches 200 liters (Fig. 11).
9. Add the fertilizers throw the upper mixer door (Fig. 12) using the amounts written
on the placard/sign according to the desired tank. Start by adding only 25-50 kg of
fertilizers (according to the fertilizers product packing size).
10. Make sure to close the upper mixer door while not using it.
11. Open water input valve again to fill additional 200 liters of water, close water input
valve.
12. Wait for fertilizers to dissolve in the water.
13. Add additional doze of fertilizers (25-50 kg) from the upper mixer door.
14. Repeat steps 11-13 until the mixer is full of 600 liters and the fertilizers have been
dissolved.
15. If the fertilizers did not dissolve and more fertilizers should be added to the mixer –
use the following steps (16-20) to dissolve the solution.
16. Open the jets valve (#3) and start pump operation using the pump operation switch
(Fig. 11).
17. Gently open the dissolving valve (#2) while checking no drops and spills are exiting
the mixer. The total blending and jets operation in the mixer can be aggressive.
18. Wait for the chemicals to dissolve.

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19. If needed to add more fertilizers to the solution (according to the fertilizer rate
table) – stop the pump operation and add the fertilizers to the mixer basket. Close
the upper mixer door and start the pump again.
20. When reaching a proper dissolvement, close the dissolving valve (#2).
21. After the chemicals have been dissolved in the tank, start mixer operation using the
pump operation switch with only the jets valve (#3) open. The water begins to swirl
and spin for additional 10 minutes with the jets. The jets suck and dissolve the
fertilizer (close to the bottom of the mixer).
22. Stop the pump after 10 minutes of operation.
23. Close all the valves in the mixer.
24. Rotate the blender operation switch to Off position.
25. The chemical solution is ready for transfer.

Solution transfer:
26. Select the desired tank by open the equivalent valve at the distribution manifold and
verify the solution input valve (Fig. 10) at the tank is open.
27. Open the solution output valve (#4).
28. CAUTION: If the pump runs for half a minute without water - it may burn!
29. Start the mixer pump using the pump operation switch.
30. When the mixer is almost empty (approximately 150 liters left) – stop the mixer
pump and close the solution output valve (#4).
31. Rotate the solution transfer valves to the Off position (distribution manifold valve
and tank solution input valve).
32. If planning to add another doze of the same solution - repeat the full process (no
mixer cleaning is required).
33. If another mix of chemicals is required or mixer operation is finished – drain and
wash the mixer - go to chemical mixer Drain and Wash procedure
34. NOTE: Do NOT use drain valve to collect solution residues. Drain line is not equipped
with filter. Unfiltered solution may cause clogging and erratic operation of the
irrigation system.

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 Dissolving
Solution output
Pump operation valve (#2)
valve (#4)
switch

Water input
valve (#1)
Jets valve (#3)

Fig. 11 – Chemical mixer operation

Upper mixer
door Mixer basket

Inspection
door

Fig. 12 – Upper mixer door

Blender operation
switch

Fig. 13 – Blender operation switch

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Refill fertilizer tank in small amounts
This procedure aims to mix small amounts of fertilizers/chemicals (less than 200 liters
mix) and fill the required tank.
This procedure is usually used for chemicals and not for fertilizers, which mostly need
greater amounts.
CAUTION: Use protective equipment while performing the next procedure as the
chemicals may spill or spray. Use a dedicated area where

Equipment:
- Protective mask and goggles.
- Protective gloves.
- 50 liters tank.
- Stirrer
- 2 X Measurement cups
- Funnel
- Fresh water port
- Ladder/stairs

Procedure:
1. Set the ladder/stairs to the top of the chemical tank.
2. Open the top cover (Fig. 14) of the tank and verify the tank is empty and clean.
3. Close the top cover.
4. Calculate the amounts of chemicals to be injected according to the chemical label
and properties as written in product manufacturer's documents and based on local
regulations.
5. Fill the tank with half of the water calculated in step No.1. For example – if we
calculated 50 liters of water with 1 liter of chemicals, add initially 25 liters of water
to the tank.
6. Add half of the calculated chemical amount to the tank.
7. Stir the mix in the tank.
8. Verify the chemicals are dissolved in the water.
9. Open the top cover of the chemical tank.
10. Carefully carry the small 50-liters tank up the ladder/stairs and pour it to the tank.
11. Repeat the procedure until the complete amount is reached.

Top cover

Fig. 14 – Chemical tank top cover

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Fertilizer tanks
There are 4 tanks, each for a specific chemical mix for the crops.
All 4 tanks can be filled from the chemical mixer.
Each tank should be placarded by number on both the tank itself and the respective
distribution manifold valves.

Solution
input port
Solution
input
Drain
valve
valve

Fig. 15 – Fertilizers tanks front view

Water input
port

Water input
Fertilizer
valve
output filter

Solution
output valve

Fig. 16 – Fertilizers tanks back view

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Wash fertilizer tank
Fertilizer tank cleaning is mostly perform after/before using a new chemical/fertilizer
mix.
Cleaning is required after containing chemicals (pesticide, herbicide, etc.).

Procedure:
1. Rotate the water input valve to the open position.
2. Add detergent (only for cleaning the tank after using chemicals - pesticide, herbicide,
etc.)
3. Wash the tank.
4. Drain valve can be switched to open position for better draining of water and
detergent residues.
5. When finish – close the water input valve.
6. Drain the tank – go to Drain procedure.

Drain fertilizer tank

One main drain line connects all fertilizer tanks and the chemical mixer to the draining
port.

Procedure:
1. Verify that the solution within the fertilizer tank require draining.
2. Rotate the drain valve to the open position (Fig. 17).
3. When tank is empty – rotate the drain valve to the close position.

Fertilizer tank
drain valve

Fig. 17 –Drain valve

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 Main drain
line

Fig. 18 – Main drain line

Electrical cabinet
Electrical cabinet is located in the pump room and comprises several electrical devices
and components for electrical stability and protection.

Fig. 19 – Electrical cabinet general view

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 Fig. 20 – Electrical cabinet upper residual-current devices

Fig. 21 – VFD overview

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 Fig. 22 – Electrical cabinet lower connection panel

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 Irrigation controller
Overview

Function keys Numeric keys +

Shortcut keys

Arrows

Menu key

PgUp PgDn

Fig. 23 – Keyboard description

Reboot button Shutdown button

Function bar

F1 F2 F3 F4
Functions

Fig. 24 – System manager menu

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Power On
Procedure:
Power On the irrigation controller from a switched off state:
1. Turning ON the Power Switch (Fig. 25).
2. Pushing the Start button (Fig. 25).

Start button

Power switch

Fig. 25 – Power supply board

Each time the software is restarted there will be some introductory screens displayed,
then the system manager screen (described below) will appear for a few seconds and
eventually the Main menu of the irrigation controller application will be displayed. The
user should wait patiently until this stage is reached.

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Power Off
CAUTION: Always turn off the irrigation controller before shutting down the main
electricity. Cutting the power before closing the open files may be a harmful action and
therefore should be avoided.
CAUTION: Do NOT turn off the power switch of the controller before the software was
commanded to shut down.
There are two options for turning off the irrigation controller:
- The Shutdown function button turns the irrigation controller system OFF.
- The Reboot function button turns the irrigation controller system OFF and then ON
again.
Both functions preserve all the data included in the controller except the statuses and left
quantities of programs.

Procedure:
1. Enter the SYSTEM MANAGER screen by pushing simultaneously the PgDn (˅) and PgUp
(˄) buttons (can be reached from any of the irrigation controller application screens).
2. Push the red function F3=Shutdown/F2=Reboot button.

Shutting down takes time, it is necessary to wait until the lights on the CPU board turn
off. Only after the lights on the CPU went off, it is safe to switch off the Power Switch (Fig.
X).

Irrigation controller manual operation

All the screens dealing with the irrigation programs definition contain a function key that
enables execution of manual irrigation operation.

Procedure
1. Select the required program for manual operation.
2. Move the cursor to the “program number” field (Fig. 26).
3. The function key F2 turns into the “Action” functions button.
4. Select the desired action to be executed:
a. Start/Stop.
b. Freeze/Release* - stopping activity until manually released.
c. Start with left - complete the left quantities according to pre inserted “left
quantities”, “left cycles” or program didn't reach its end.
d. ENABLE Completion** - the system will try to complete leftovers from
uncompleted dosage.
5. Press function key F2=Active to execute the command.
6. Monitor the execution.

*The "Freeze" option can freeze the whole system, freeze specific programs or individual
lines. "Freezing" individual lines is enabled only in the WATER DOSAGE screen, where the
line number is specified.

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**ENABLE Completion – is an option that can be activated per each program individually.
Once activated, the option remains active until de-activated. When a program with an
active “Enable completion” feature reaching the end, it will check whether some of the
included valves have uncompleted dosage (probably because of some malfunctions).

"Program number"
field

Action button

F1 F2 F3 F4
Functions
Fig. 26 – Water dosage menu

System alarms and troubleshooting guide

For system alarms and basic troubleshooting guide – go to Irrigation controller
troubleshooting guide.

Manual filter flushing

Manual flushing may be needed in several situations, for example – low water quality,
weekly maintenance, etc.

Procedure:
1. Open the flushing controller cover (Fig. 27).
2. Manually activate the flushing sequence by pushing the “Manual” key on the
flushing controller (Fig. 27).

3. When manually activated, the icon will appear on the display.

4. The “Manual” key will be used also for manually terminating a sequence in progress.

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 Enter key Manual key

Minus - Plus +

Fig. 27 – Flushing controller

Check filter flushing accumulations

The controller accumulates and displays the number of flushing cycles caused by DP, by
time, or manually.

Procedure:
1. Click on Enter key to view filter flushing accumulations (Fig. 27).
2. It is possible to clear the accumulated values using the Plus or Minus keys.

Fertilizer table

Fertilizer table calibration

Calibration should be made only when the fertilizer flow shows high/low flow in respect
to the marked flow rates on the flow rate indicator tube.

Procedure:
1. Start fertigation using the required fertilizer tank.
2. Check the marked required flow rate (Fig. 29).
3. Check current flow rate (Fig. 29).
4. Rotate the calibration knob gently and wait a few second for the flow rate to
stabilize (Fig. 29).
5. Continue calibrating gently until the required flow rate reached.
6. If fertigation is performed especially for the calibration process – fertigation may be
stopped.

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 Calibration
knob

Flow rate
indicator

Fig. 28 -Fertigation tables

Flow rate Marked Calibration

indicator required flow knob

Fig. 29 – Flow rate indicator and calibration knob

Main irrigation valves manual operation

Manual operation of main irrigation valves (Greenhouse, open fields and plantations) is
required for several maintenance operation.
CAUTION: Do not use this procedure unless directed from another procedure.

Open field and plantation procedure:

1. Verify the respective valve is an AUTO position (Fig. 31).
2. Rotate the valve to OPEN position.
3. After the procedure is completed, move the valve back to the AUTO position.

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Greenhouse procedure:
4. Greenhouse valve has only OPEN/CLOSE options. Verify it is OPEN (Fig. 30).
5. Rotate the greenhouse pump valve to 'H' position (Fig. 32).
6. After the procedure is completed, move the greenhouse pump valve to the AUTO
position.

Fig. 30 – Greenhouse main valve

Fig. 31 – Open field/plantation main valve

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 Fig. 32 – Greenhouse pump switch

Irrigation backup infrastructure

Irrigation backup infrastructure provide bypasses from one system to another (open
field, plantation and greenhouses) using the backup bridge located just outside the
control room (Fig. 33).
The backup bridge connects all the output pipes with respective valves in order to
enable irrigation in cases where one irrigation system (open field, plantation and
greenhouses) is not functioning.
Valves position for standard operation are showed in Fig. 33.

Procedure:
1. Define the non-functioning system.
2. Open the backup bridge valve of the non-functioning system.
3. Open the backup bridge valve for the water provider system.
4. After irrigation is complete – close all backup bridge valves.

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 Backup bridge
valves

Backup bridge
Open fields
output

Plantations Greenhouse
output output

5.
Fig. 33 – Backup bridge

Open fields
output pipe

Greenhouse
output pipe Plantations
output pipe

Fig. 34 – Backup bridge tunnel view

Electrical failures
In case of an electrical failure the failed systems need to be operated manually.
There are several options for electrical failure:

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- General failure
- Irrigation controller failure
- Fertilizer table failure
- Pumps failure

General electrical failure – needs to be recover ASAP as none of the critical devices of
the irrigation system works with no electricity.
Call electrician or other maintenance service ASAP.

Irrigation controller electrical failure - when the irrigation controller senses no power
input, it starts working on battery power to maintain connection to the on-line server
and to save the current status of the system. It doesn't utilize irrigation plans and
doesn't offer many functionalities.
For additional information regarding No AC alarm – go to No AC section in the Irrigation
controller troubleshooting guide.

Fertilizer table electrical failure – irrigation water passes through the fertilizer table even
when the fertilizer table doesn't work properly. Fertigation is not available for the field
until malfunction is fixed.
In greenhouse fertilizer table may need to switch the pumps operation switch to 'H'
position for normal operation (Fig. GHP in Main irrigation valves manual operation).

Pump electrical failure – depend on the malfunctioned pump, the pump needs to be
fixed soon to provide the required flow rates and pressure to the irrigation system. The
system may work in a degraded mode with smaller flow rates.
Call electrician or other maintenance service.

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