Gazeeka Model 180s Service Guide
Version 2024
Definitions
Parts Breakdown
Model 180s Wiring Diagram
Error Messages
“No Connection” can only be one of three things:
- A connector has popped out/pins not seated correctly inside connector (inside the Active Antenna – right-hand side) or,
- A faulty Baler Harness or connector in the Baler Harness (connection between the touch screen and the antenna) or,
- A faulty Control Module in the Active Antenna (typically no LEDs flashing on top board).
Troubleshooting Process
Power on the Gazeeka and take the lid off the Active Antenna.
- No LEDs flashing
- No power
- This can be confirmed by measuring the voltage at the power-in connector on the Microwave Module (highlighted red on the wiring diagram below).
- Check the two pin power connector that comes in from the bottom of the antenna and into the bottom board (Microwave Module). There is a chance that the connector itself has popped out, or more likely that the pins are not seated correctly in the connector. If the latter is true, use a pair of pointy-nose pliers to correctly seat pins.
- If the above seems ok, then it is likely the Baler Harness (Touch Screen to Active Antenna) is causing the issue and needs to be repaired (see below) or replaced.
- Trace the entire length of the Baler Harness to find where the potential issue is coming from (likely crushed or pinched somewhere) or use the harness tester in the Gazeeka First Aid Kit (870s-AID-R00).
- If power is measured at the Microwave Module, but no LEDs are apparent it is likely that the Microwave Module has failed.
- If power is measured at the Microwave Module, LEDs are apparent, but no power is measured at the power-out connector (highlighted purple on the wiring diagram below) the Microwave Module will need to be replaced.
- No power
- Green LED flashing on Microwave Module and red LEDs flashing on Control Module
- Faulty communications connection via Baler Harness – harness needs to be repaired (see below) or replaced.
- Green LED flashing on the Microwave Module only
- Check the two pin harness that runs between the two boards (connectors may have popped out or pins not seated correctly – give them a wiggle).
- If above harness seems ok, check voltage at either ends of this harness (measure where the pins are soldered to the boards – careful not to create a short).
- If there is good voltage at the top board (highlighted orange on the wiring diagram below), it is likely a failed Control Module – need to replace Control Module – following repair notes below first.
Repair Notes:
If an electrical cable is suspected of being faulty, it needs to be tested before any other components are replaced. A shorted-out cable is capable of potentially destroying any replacement module, thus compounding the issue.
If you suspect a cable fault, use a new cable and lay it around the hay baler and connect it in at both ends (terminal in the tractor and Instrument at the rear of the baler). Power up and if this works OK, replace the faulty baler cable. If this does not power up and work OK, then commence replacing modules in the antenna still using the test cable until the system is OK. To determine which component is at fault.
Testing a cable with connectors at each end (“belling it out”)
The following assumes the connectors are labelled A, B, C …etc. The same applies to any other labelling of a connector such as 1, 2, 3 … etc.
Testing a multi-core cable with connector on each end by testing between pins “A” on one end to pin “A” on the other end, then B, C etc. tests the continuity of the cores, but it does NOT test if any of the cores are shorted out.
To tests if cores are shorted out one needs to test between pin A on one end then B, C, D etc. (all other pins) on the other end to make sure there is NO continuity, then between pin B on the same end and pins C, D, E etc. then pin C on the same end and pins D, E, F etc. until all pins are tested against all other pins for isolation.
Using the harness tester to test a harness
If your dealership has purchased a Gazeeka First Aid Kit (870s-AID-R00) – inside that kit will be a harness tester. The harness tester comprises of a transmitter (larger module) and a remote terminator. There will also be numerous connectors in the kit for plugging into the harness tester, that will allow the testing of different generation harnesses and sections of the harnesses.
The process is very simple. Find the connectors suitable for testing the potentially faulty harness you wish to test. Plug one into the left-hand side port of the transmitter (there is a small arrow above the text “LANtest” point to the correct port) and the other into the remote terminator. Then, plug each module into their respective ends of the harness you wish to test. Once both are connected, on the transmitter slide the switch to ON and make sure the button left of the switch (AUTO/MANUAL) is compressed (AUTO mode). The transmitter will then start to send a signal through each of the wires, one after another. Now, go to the end of the harness where the remote terminator is located and watch the LED’s light up 1 – 8 (ignore G/GND). If an LED (or multiple) is missed in the sequence, this indicates an issue with that wire. Physically inspect the harness to find where the issue is coming from for that corresponding wire. Consult the Owner’s Manual or “Harness Configurations” (Baler Harnesses) section of this guide for electrical drawings.
There is a good chance this is caused by a poor air reading (potentially part of a bale or another form of obstruction was apparent during the air calibration).
Conduct a new air calibration, making sure there is nothing in between the two antennae and they have a clear line of sight of each other. It is best practice that there is no hay within 2 feet of the antenna beam.
Note that for very dry hay (less than 8%), the microwave signal will be close to the Air Calibration signal strength. So, an occasional “No Bale” or “Low Moist”when a bale is present may occur. This just means that the hay has a very low moisture content.
If this does not fix the issue, a factory reset may be required.
Enter the Dealer Menu
- From main screen
- F1 > MENU > Service Menu A > 8001
- Use the ITEM key to find “Down to Reset” in the menu.
- Press the DOWN button.
- Once the screen shows “parameters reset” flick the terminal off for 30 seconds and then flick it back on.
- Treat as new instrument – check set parameters, alarm level and crop type are correctly entered.
- Wait for the instrument to warm up (2 minutes) and then do a new Air Calibration.
As the error code suggests, the Gazeeka system isn’t getting enough power. It is best to start at the source and work your way forward.
Troubleshooting Process
Check the switch or plug where the Gazeeka console is getting the power from. Using a multimeter check that the power source is giving at least 13v (tractor running). If this is ok, move to the following step.
Using the multimeter, check the power is ok coming into the Gazeeka. This is done by measuring across the two-pin Molex connector (power in) on the Microwave Module (highlighted red below). This should be >13v when the tractor is running (be careful not to short this out!).
If there isn’t >13v (tractor running), there is likely an issue with Baler Harness. However, if this looks ok, then there might be an issue with the chip that measures the voltage at the Microwave Module, this can be fixed as per below.
Changing 12v Limit
- From Analyse Mode, press F1
- Use the MENU button to find Service Menu A
- Change the Service Code to 8001
- Use the ITEM key to locate 12v Limit
- Change to 11
If this doesn’t fix the issue, the Microwave Module will need to be replaced.
This generally means that the Air Calibration values are higher than the max (attenuation > SAA Max).
Troubleshooting Process
First check for a loose or damaged Microwave Harness. This could be a kinked or crushed section of the harness. Following on from that, check the connection at either end to the antenna, this can be done by ensuring the connection is finger tight and if you gently wiggle and pull on the connection nothing comes loose.
It could also mean that a bale was still in the chamber or something obstructing the microwaves. Check that there is nothing in between the antennae, they have a clear line of sight and no hay within 2ft of faces.
Check SAA Max and Compare to MW Mode
- From Analyse Mode, press F1
- Use the MENU button until you reach Service Menu A
- Change Service Code to 9000
- Now, use the MENU button until you reach Tol Parameters.
- Use the ITEM button to find SAA Max (write this value down).
- Use MENU button to find Service Menu B
- Use the ITEM button until you reach MW Mode
- Press the UP button and make the parameter YES
- Press the ENTER button
- What is the attenuation (it is the smaller number)?
If attenuation is slightly higher (1-5) than the SAA Max (previously written down), then increase the SAA Max to just above the SAA measured through MW Mode.
Note: If the MW Mode attenuation reading (SAA) is less than 12 or greater than 50, this is a sure sign of a failed Microwave Module – this will need to be replaced. Typical readings are 16 – 21 (SAA) and 13,000 – 23,000 (SDA). This assumes that the gain values have been loaded correctly, before deciding to replace the Microwave Module check the systems gain values as per the instructions below. This number could be greater for double balers.
Checking the gain values (v9p0 Microwave Modules ONLY – S/N 4150 – present)
Ensuring that the Microwave Module gain values are correctly loaded into the Control Module is crucial (S/N 4150 – present). Incorrect gain values can cause abnormal attenuation readings and prevent the system from passing an Air Calibration (EA Error).
Finding the gain values:
- The gain values are recorded on the Microwave Module, as shown below:
Checking the gain values:
- From Analyse Mode, press F1
- Press the MENU button to find Service Menu A
- Press the UP button to make the Service Code 8001
- Press the MENU button to find Dealer Menu
- Press the ITEM button until you find Show Gains
- Press ENTER
- Compare the screen values to the those written on the Microwave Module
- If they are different, you will need to overwrite them using the steps below
Overwriting the gain values:
- From the Dealer Menu, press the ITEM button and confirm the following parameters
- 7 Gain Def ‘No’ (if YES, change to NO)
- 8 Gain Def ‘No’ (if YES, change to NO)
- 9 Gain Def ‘No’ (if YES, change to NO)
- Now, use the ITEM button to find the gain value parameters
- 9 A Ratio “XX.XX” (change to value recorded on Microwave Module sticker – use the FIELD button to move cursor across and UP/DOWN to change values)
- 9 VMX Off “XX.XX” (change to value recorded on Microwave Module sticker – use the FIELD button to move cursor across and UP/DOWN to change values)
- 9 F1A “XX.XX” (change to value recorded on Microwave Module sticker – use the FIELD button to move cursor across and UP/DOWN to change values)
Factory Reset
If the values from the MW Mode look ok and the gain values are loaded correctly, but the unit still wont pass an Air Calibration (EA Error) then there may be some corrupt parameters in the system. To clear the system of any corrupt parameters, a factory reset can be used.
Enter the Dealer Menu (newer units)
- From Analyse Mode, press F1
- Now press MENU until you find Service Menu A
- Change the Service Code to 8001 and then press MENU
- From Dealer Menu A
- Use the ITEM button to find “DOWN to Reset”
- Press the DOWN button – “Parameters Reset”
- Reboot the terminal
- Wait for the instrument to warm up (2 minutes) and then follow the visual step-by-step guide to setting up and calibrating your instrument in the Gazeeka Model 180s Quick Start Guide.
Link here: https://vomax.com.au/documentation/model-180s-quick-start-guide/
This error code normally means that microwave reflections are occurring.
- Firstly, check that there is no obvious obstructions between the antennas. This could come in the way of tailgate chains running straight through the face of the antenna, tailgate is in the up position or any other metal obstructions.
- If this seems ok, check the Microwave Harness running between the two antennas for any physical damage, as a pinched, crushed or bent harness can cause reflections. It is also important to check the connections inside the antenna housings. To do this, take both lids off and check that the SMA connections are ok (gently pull/wiggle the connector to make sure it is snug and check that it is finger tight).
- If this seems ok, continue as per below.
Next we will check the Air Calibration values, making sure there was no distortion when the Air Calibration was done.
- From Analyse Mode, press F1
- Use the MENU button to find Service Menu A
- Change the Service Code to 9000
- Use the MENU button to find Last Measurements
- Use the ITEM button to find SDA
- What is the SDA? Shouldn’t be much higher than 23,000 (record value)
- What is the SAA? It shouldn’t be much higher than 16 – 21 (record value)
- Use the ITEM button to find SDA
Now, compare the Air Calibration values to a microwave tests (raw microwave readings)
- From Last Measurements, press the MENU button to find Service Menu B
- Use the ITEM button to find MW Mode
- Press the UP button and make the parameter YES
- Press ENTER (record values)
-
- If the SDA is in the 13,000 – 23,000 range (second set of numbers) then this is acceptable and also that the SAA is ok (typically 16-21)
- The values should closely resemble the Air Calibration values you just recorded
- If the numbers are within the parameters just mentioned, go ahead and do a new Air Calibration
-
- From Service Menu B, press the MENU button to find Setup Menu
- Press the ITEM button to find ENT for Air Calibration
- Follow the screen prompts
- If the Air Calibration fails (EA Error) go ahead and preform a “DOWN to reset” (outlined below)
- If the numbers are well outside the typical numbers quoted, there is a good chance that there is an issue with the Microwave Module
- Preform a “DOWN to rest” (outlined below). If this does not fix the issue, refer to the “Replacing Modules” section of this guide
Preforming a “DOWN to Reset”.
Enter the Dealer Menu (newer units)
- From Analyse Mode, press F1
- Now press MENU until you find Service Menu A
- Change the Service Code to 8001 and then press MENU
- From Dealer Menu A
- Use the ITEM button to find “DOWN to Reset”
- Press the DOWN button – “Parameters Reset”
- Reboot the Touch Screen
- Wait for the instrument to warm up (2 minutes) and then follow the visual step-by-step guide to setting up and calibrating your instrument in the Gazeeka Model 180s Quick Start Guide.
Link here: https://vomax.com.au/documentation/model-180s-quick-start-guide/.
The “Reject” or “Distn” message is displayed when there are spectral distortions in the microwave signal to such an extent that we have considered this may give erroneous moisture readings.
Geometric causes: This can be caused by a number of things. Sometimes this is caused by wet and dry “layers” of hay being next to each other or unusual size “lumps” of very wet hay or the leading or trailing end of a wet bale. Often you can get this spectral distortion effect by placing your body in front of the antenna. Most times these distortions are determined by the physics and the geometry of the situation and the only resolution is to remove the cause of the distortion.
Component causes: It is also possible for an electronics fault in the microwave module to cause a spectral distortion. The microwave boards are tuned to remove internal distortion, however if the tuning screws have been tampered with (the holes in the back of the aluminum block) or a component has failed, this may cause the microwave spectrum to appear distorted and be rejected. This would be rare, and we have never seen it in the field, only when first tuning new boards at the factory.
Changing rejection values: The two parameters concerned are ADrej and DDrej (DDrej is typically zero and Drej 25 as default). Sometimes changing this value to say 30 can fix or reduce the problem, but it should not be made any larger than this.
Removing the test: You can remove this spectral distortion test by setting both “ADrej” and “DDrej” to zero. However, we do not like doing this, but if the end user believes that there are no anomalous readings being caused when this is done, then this could be a solution.
If you are experiencing suspected spectral distortions in the microwave signal, it is suggested that you open a support ticket with the technical support team.
Open a ‘Support Ticket’ here: https://db.samj.us/support/create.
In Gazeeka Model 180 units the Control Module does all the processing using the microwave data sent from the Microwave Module. If the communications between the two modules is lost, the system will display “No Comms”.
The communications harness between the two modules is labelled 870-E41 and is highlighted red in the wiring diagram below.
Troubleshooting Process
- Power up the Gazeeka and take the lid off the Active Antenna
- Check the harness between the two modules. Make sure the connectors are firmly plugged in and the pins are seated correctly.
- Gently tug on all the wires where they enter the molex connector to ensure they the pins are well crimped.
- Look to see if the Control Module LEDs are flashing, if they are and the Microwave Module LEDs are not, this would indicate a dead Microwave Module.
- Note: this assumes that power is ok (see the “No Connection” section of Error Messages for instructions on checking power)
- If the Microwave Module LEDs are flashing and the Control Module LEDs are not, then it may be a dead Control Module
- Note: this assumes that power is ok (see the “No Connection” section of Error Messages for instructions on checking power)
- Check the harness between the two modules. Make sure the connectors are firmly plugged in and the pins are seated correctly.
Note: “No Comms” will also occur if a replacement Microwave Module is put in that does not have compatible operating software (see the “Replacing Modules” section of this guide).
“Waiting” could mean there is a corrupt parameter in the systems memory and there may be a requirement to do a factory reset. Resetting the instrument to its original factory settings is a last resort, intended to clear any corrupted parameters after all previous troubleshooting attempts have been exhausted.
Factory Reset
- Enter the Dealer Menu
- From Analyse Mode, press F1
- Now press MENU until you find Service Menu A
- Change the Service Code to 8001 and then press MENU
- From Dealer Menu A
- Use the ITEM button to find “DOWN to Reset”
- Press the DOWN button – “Parameters Reset”
- Reboot the terminal
- Wait for the instrument to warm up (2 minutes) and then follow the visual step-by-step guide to setting up and calibrating your instrument in the Gazeeka Model 180s Quick Start Guide.
Link here: https://vomax.com.au/documentation/model-180s-quick-start-guide/.
OV Range = Over Range which means the microwave signal that is being measured is weaker than the limits we have set internally.
Assuming the system is not trying to measure very high moisture hay (e.g. balage/halage) and there is no physical damage to the antennae, this could be caused by a broken Microwave Harness or a faulty Microwave Module.
Initially check the antennae have not been knocked or damaged. If using break-away brackets, ensure that the antennae are correctly positioned so they are facing each other. Next, check the Microwave Harness for any obvious damage. This could be a kinked or crushed section of the harness. Following on from that, check the connection at either end to the antenna, this can be done by ensuring the connection is finger tight and if you gently wiggle and pull on the connection nothing comes loose.
Unlikely, but a memory corruption could cause this. So, if the above does not fix the issue there may be a requirement to do a factory reset. To reset the instrument to its original factory settings and attempt to clear any corrupted parameters, this action should be reserved for ’emergency’ situations, only after all prior troubleshooting steps have failed. It is recommended that any factory resets be performed by a certified Gazeeka technician.
Alternatively, please contact our support team for assistance: https://db.samj.us/support/create.
Factory Reset
- Enter the Dealer Menu
- From Analyse Mode, press F1
- Now press MENU until you find Service Menu A
- Change the Service Code to 8001 and then press MENU
- From Dealer Menu A
- Use the ITEM button to find “DOWN to Reset”
- Press the DOWN button – “Parameters Reset”
- Reboot the Touch Screen
- Wait for the instrument to warm up (2 minutes) and then follow the visual step-by-step guide to setting up and calibrating your instrument in the Gazeeka Model 180s Quick Start Guide.
Link here: https://vomax.com.au/documentation/model-180s-quick-start-guide/.
After setting the instrument back up, check that it passes an Air Calibration.
If the Air Calibration is OK, disconnect the Microwave Harness in the right-hand antenna and let it hang loose. There will be a weak signal still getting through just like a very high moisture bale. If an error message comes up (like a phase error) or a moisture reading above 26%, then the microwave system is reading well at both ends of the scale. Reconnect the Microwave Harness.
If the above does not fix the issue, the Microwave Module needs replacing. Refer to the “Replacing Modules” section of this guide.
Moisture Readings
How it Works
Gazeeka instruments use microwaves to measure moisture in hay bales. These microwaves move through the hay at different speeds depending on how much moisture is present. Dry hay slows the microwaves slightly compared to air, but water slows them much more. The instrument measures how fast the microwaves travel through the bale and how much energy they absorb. Gazeeka has engineered advanced hardware and software to transmit, receive and analyse these signals, thereby providing precise moisture readings for hay bales.
When a bale enters the microwave beam, the system detects its presence and monitors changes in the microwave signal to determine movement. It waits until the bale has sufficiently passed through the beam before converting microwave readings into moisture content. This ensures that the entire detected microwave signal has travelled through the bale and not some of the single going around the end of the bale.
For reliable moisture measurement, three key factors are crucial: a good air calibration, correct bale width setting, and selecting the right equation for the type of hay. Once set, the first two factors typically remain stable unless the baler or microwave system undergoes significant changes. In newer models, entering the approximate size and weight of the hay bale further enhances measurement accuracy by considering its bulk density.
Not all microwave moisture sensors are built the same. It’s crucial that the microwave technology have sophisticated software and hardware that will last from one baler to the next.
Understanding the Limitations of the Readings
Comparing with Other Moisture Measurement Methods:
Other methods, like conductivity, are sometimes used to measure moisture in hay bales. These methods might give different readings compared to the Gazeeka instrument. While these alternatives may not be as precise as the Gazeeka, they could be the standard for payment or the method you’ve used previously. It’s important to acknowledge these differences until you’re confident in your new Gazeeka instrument.
For cured legume and cereal crops, evidence suggests conductivity readings will read several points higher than the microwave system. However, over a few days, conductivity readings tend to align more closely with the Gazeeka readings taken on the day of baling. For crops that aren’t cured, the difference in readings may be more significant, and they might not converge over time.
Research indicates that conductivity methods may not provide accurate real-time measurements of bale moisture during the baling of steamed hay. This discrepancy arises because surface moisture on the hay causes conductivity readings to register several points higher than the actual moisture content. Conductivity sensors operate by seeking the path of least resistance, and surface moisture conducts more readily than the overall moisture profile of the hay being baled.
Hay Additives:
Overdosing additives can affect both microwave and conductivity methods, although conductivity methods are typically impacted more. Some hay additives, especially propionic acid, will affect the performance of the moisture readings more than others. Propionic acid, unlike most additives, requires you to increase the dose rate as the moisture content increases, leading to very high dose rates at high moistures. Typical additives on the market don’t significantly affect the performance of the Gazeeka instrument when used at recommended doses.
Hay Spoilage:
Hay spoilage or even spontaneous combustion is not caused by moisture content alone. Spoilage depends on factors like bacteria, yeast, mold levels (measured in CFU/gram), water-soluble carbohydrates (sugars), oxygen levels, and moisture content. The presence of bugs and sugar content varies with factors such as time down, seasonal conditions, cutting time and other factors. Hay is at higher risk of spoilage if cut before the plant fully matures. This will slow the drying of most types of hay and is especially noticeable when the growing season has had a dry finish (drought conditions).
These considerations are crucial for making informed decisions about when to bale and at what moisture levels, particularly for preventing spoilage and ensuring hay quality. We strongly recommend consulting the Operator’s Manual for a thorough understanding of how the system operates and its limitations. This section only provides a high level overview.
A good way to verify the moisture of your hay is through your humble microwave oven at home. It can take a few trials to become comfortable with the process, but it’s an absolute method for determining the moisture content of a sample. Please note, it is fundamental to understand the importance of representative sampling and how the sample you pulled represents a bale, windrow or field. We’ve created an easy to follow document to assist in best practice when it comes to sample collection and moisture analysis.
Link here: https://vomax.com.au/documentation/sampling-and-analysis-of-hay-moisture/.
For reliable moisture measurement, three key factors are crucial: a good Air Calibration, correct bale width setting, and selecting the right equation for the type of hay. Once set, the first two factors typically remain stable unless the baler or microwave system undergoes significant changes.
CHECK LIST
- Make sure the correct equation (crop type) has been selected in Analyse Mode (exert from Quick Start Guide below)
- Check all Set Parameters are entered correctly
- From the Analyse screen, press F1 and then MENU
- Now use the ITEM button to cycle through all the parameters in this menu
- Conduct a good air reading
- From Set Parameters press MENU, until you find Setup Menu
- Press ITEM and follow the screen prompts
For visual, step-by-step instructions and best practices, see pages 9-13 (Setting Up Your Moisture Meter and Editing Instrument Parameters) and page 14 (Air Calibration) of the Quick Start Guide.
Link here: https://vomax.com.au/documentation/model-180s-quick-start-guide/.
If the above is ok, enter the Dealer Menu
- From the Analyse screen
- Press F1 and then MENU, until you find Service Menu A
- Change the Service Code to 8001 and then press MENU
- Now check the air reading values
- Use the ITEM key to find SDA (this should be around 13,000 to 23,000).
- Use the ITEM key to find SAA (this should be around 16 to 21).
- If SAA is around 40 or more, then the chances are the Air Calibration was done with a bale (or something else) either in the beam or partially in the beam. Clear the air path (no bale or anything else within 3 feet of the antenna beam) and do a new Air Calibration. If the Air Calibration is still wrong, replace the microwave module with the correct version replacement (see ‘Replacing Modules’ section of this guide).
For new users it is sometimes difficult to come to grips with the fact that we are calibrated to “oven dried moisture” which is the industry laboratory standard and not some arbitrary conductivity readings from a conductivity meter whose manufacturers may not say what it is calibrated against.
If “Version A” above does not fix the issue, there may be a requirement to do a factory reset. To reset the instrument to its original factory settings and attempt to clear any corrupted parameters, this action should be reserved for ’emergency’ situations, only after all prior troubleshooting steps have failed. It is recommended that any factory resets be performed by a certified Gazeeka technician.
Alternatively, please contact our support team for assistance: https://db.samj.us/support/create.
Factory Reset
- Enter the Dealer Menu
- From Analyse Mode, press F1
- Now press MENU until you find Service Menu A
- Change the Service Code to 8001 and then press MENU
- From Dealer Menu A
- Use the ITEM button to find “DOWN to Reset”
- Press the DOWN button – “Parameters Reset”
- Reboot the terminal
- Wait for the instrument to warm up (2 minutes) and then follow the visual step-by-step guide to setting up and calibrating your instrument in the Gazeeka Model 180s Quick Start Guide.
Link here: https://vomax.com.au/documentation/model-180s-quick-start-guide/.
Screen Related Issues
Reduce screen brightness: tap left-hand side of display
Increase screen brightness: tap right-hand side of display
LCD goes straight into Analyse Mode, begins to read moisture, but doesn’t respond to key strokes and still makes the ‘beep’ sound for all keys.
Take the lid off the Active Antenna and check that the LEDs are flashing on the Microwave Module and Control Module. This will determine if the power connection is ok.
- If power appears to be ok, then it is more than likely the communication wires that carry the key strokes from the terminal to the module in the Active Antenna that is causing the problem. This means that either the Baler Cable needs to be replaced or the wires repaired (instructions can be found in the “Error Messages” section under “No Connection”).
Microwave Check
All Gazeeka Model 180s instruments have a check module mounted in the Passive Antenna. A description on how to use this is in the owner’s manual, but is repeated below for reference.
If the instrument is measuring the full dynamic range, it is highly unlikely there is anything wrong with the microwave measuring system.
In-Built Calibration Check
Your Gazeeka instrument has a CCM in the Passive Antenna (the one without the electronics in it on the left-hand side of the hay baler).
The combination of doing a normal Air Calibration and then a CCM check will confirm that the Microwave Module is reading the microwaves correctly across the whole dynamic range, from dry to wet hay.
A. Dry End: The Air Calibration checks that the strongest signals which are present without a hay bale being present are being read correctly.
B. Wet End: The CCM reading checks that the weakest signals which are present with a very wet hay bale being present are being read correctly. This is done by inserting the CCM into the circuit with no hay bale between the antennae and doing the test.
A. Do an Air Calibration as follows (with the tractor running):
Doing an Air Calibration is one of the most important steps when setting your Gazeeka moisture meter up for baling. This not only sets the reference point for the moisture readings, but it is also a good system check to ensure your unit is operating correctly.
Before you start:
- Make sure the instrument has been on for at least 2 minutes (tractor running)
- Make sure the air path between the antennae is clear (i.e., no bale, chains, tailgate or anything else is obstructing the microwave path)
- Ideally, the bale chamber should be completely empty of hay or at the very least the end of the bale should be inside the rear end of the baler doors and thus, no bale within 600mm/2′ of the sensors
Air Calibration:
- From Analyse Mode, press F1
- Press ITEM to find ‘ENT for Air Cal’
- Press ENTER and follow the screen prompts
For visual, step-by-step instructions and best practices, see page 14 (Air Calibration) of the Quick Start Guide
B. Do a Calibration check reading as follows (with the tractor running):
Putting the CCM in the circuit:
- Take the cover off of the Passive Antenna (the one without the electronics in it on the left-hand side of the hay baler).
- Unscrew the Microwave Harness from the central antenna connector.
- Unscrew the microwave cable on the CCM and screw it onto the central antenna connector.
- Screw the Microwave Harness coming from the other antenna on the end of the Calibration Check Module (see photo below).
Conducting the CCM test:
Make sure the air path between the antennae is clear (i.e. no bale or anything else). The end of the bale should be inside the rear end of the baler doors by at least 2′.
- From Analyse Mode, press F1 (Setup Menu)
- Now press the ITEM button and find “ENT to Test”
- Press ENTER and follow the screen prompts
If no error message is displayed, then the following message should come on the screen “XX.X% PASSED” (XX.X% should be approximately 20% – +/- 1%). If the rest failed, it will show “XX.X% FAILED“.
Once the test has passed, disconnect the CCM and screw the Microwave Harness back into the central connector in the Passive Antenna. Put the lid back on the Passive Antenna, making sure not to tighten the fasteners too much and crush the rubber washers. Now, put your aerosol cans back in the marker units and put the unit back in Analyse Mode.
Replacing Modules
Microwave Module 7p2 – Fast interface. Only some second-hand refurbished modules are now left (all 180 controller modules operate the fast interface)
Microwave Module 8p0 – Form fit and function compatible with 7p2 and 9p0, but different gain values
Microwave Module 9p0 – Form fit and function compatible with 7p2 and 8p0, but different gain values
Control Module D1431-1 – Replaced by Control Module D1445
Control module D1445 – Currently used module
Notes:
- All of the 7p2 Microwave Modules can be reprogrammed in the factory to be compatible with Gazeeka 180 units up to and including 2023 models.
- The fast interface was introduced in August 2014: 7p2 version 1p06 (before the 180 was introduced)
- The 9p0 module was designed when some electronic chips used in the 8p0 module were no longer available during the Covid-19 pandemic.
Serial number 1800 to 1874 (E01) used v7p2 Microwave Modules and D1431 Control Modules (these units are not compatible with 8p0 or 9p0 Microwave Modules as they were delivered). Repairs could be as follows:
- Microwave Module failure, replacing the 7p2 Microwave Module with a re-furbished 7p2 module if one is available, loaded with software version 1p11. Otherwise, upgrade as described below.
- Upgrade the code in the D1431 Control Module (v21p06) to support the v8p0/v9p0 Microwave Modules and replace the failed v7p2 Microwave Module with v9p0 Microwave Module.
- Control Module failure, replace D1431-1 Control Module with a re-furbished D1431-1 with latest code (if available). Otherwise, a new D1445 needs to be loaded.
Serial number 1875 to 1972 (E01) used v8p0 Microwave Modules and D1431 Control Modules. Repairs could be as follows:
- Microwave Module failure, replace the 8p0 Microwave Module with a new 9p0 Microwave Module.
- Control Module failure (S/N 1875 to 1926), replace D1431-1 Control Module with a re-furbished D1431-1 with latest code (if available). Otherwise, a new D1445 needs to be loaded.
- Control Module failure (S/N 1927 to 1972), replace with new D1445 Control Module.
Serial number 1973 to present (E01) used v9p0 Microwave Modules and D1445 controller module. Repairs could be as follows:
- Microwave Module failure, replacing the 9p0 Microwave Module with a new 9p0 Microwave Module.
- Control Module failure, replace with new D1445 Control Module.
Please note that over the years a number of Gazeeka Model 180 instruments have been updated / upgraded (particularly in the USA) and the factory has no record of which serial numbers have been changed. It is often good practice to take a photograph of the electronics in the Active Antenna (with any version number that can be seen on a round green sticker) and send it to your dealer or create a support ticket with a clear description of the problem, make and model of baler, and your contact details.
Open a ‘Support Ticket’ here: https://db.samj.us/support/create.
CHECK THE MODULE COMPATIBILITY SECTION BEFORE CONTINUING.
Equipment List
- Box cutter (fine knife)
- 8mm open spanner (5/16″ wrench) for SMA connectors (or fingers OK).
Procedure
- Make sure the power is off.
- Unplug the white Molex connectors on the edge of the Microwave Module assembly, noting which ones go where (highlighted purple above).
- Using the box cutter you may need to gently break the silicon seal between the mounting plate and antenna housing. Then gently slide the plate out to get better access to the SMA connectors.
- Using the 8mm wrench (or fingers) undo the SMA connectors (two) on the microwave board (highlighted red above).
- To reassemble, reverse this procedure. Refer to the wiring diagram above to show which Molex connectors go where. The SMA connectors should be tightened to no more than 1Nm torque. If you do not have a torque wrench, tighten as firmly as you can using your fingers (they won’t come loose). Don’t use any other mechanical means.
- Replacement complete. If this is an upgrade, follow the upgrade procedure. If not, then power up and enter any parameters that need to be entered, then do an Air Calibration.
CHECK THE MODULE COMPATIBILITY SECTION BEFORE CONTINUING.
Equipment List
- Box cutter (fine knife)
- 8mm open spanner (5/16″ wrench) for SMA connectors (or fingers OK).
Procedure
- Make sure the power is off.
- Unplug the white Molex connectors on the edge of the Control Module assembly, noting which ones go where (highlighted below).
- Using the box cutter you may need to gently break the silicon seal between the mounting plate and antenna housing. Then gently remove the Control Module on the mounting plate.
- To reassemble, reverse this procedure. Refer to the wiring diagram below to show which Molex connectors go where.
- Replacement complete. If this is an upgrade, follow the upgrade procedure. If not, then power up and enter any parameters that need to be entered, then do an Air Calibration.
Module LED Meanings
Microwave Module (V8p0/V9p0)
Firmware versions 1.xx to 2.xx (most recent)
LED H501: Blinks when powered on and operating normally
LED H502: Blinks whilst reading microwaves
Note: 1.06 was first to use high speed Baud rate to the Control Module.
Versions 1.00 to 1.05 are not compatible with current spare Control Modules.
Firmware versions 9.xx to 15.xx (older versions)
LED H501: blinks whilst reading microwaves
LED H502: Not Used
V7p2 Microwave Module: the LEDs are located above the DIP switches.
D1431 / D1445 Controller Modules
LED A Flashes with each RS422 transmission. Goes off once an ISOBUS link is established.
LED B Flashes with ISOBUS communicating (off until the link is established).
LED C Flashes with each transmission received from the Microwave Module.
LED D Flashes on bale marking (if this does not flash when the marker push button on the D1431-1 is pressed, then this will indicate dead code).
LED ABCD All flash in sequence whilst new code is being loaded (via Bluetooth connection or USB memory stick).
Thus, if there are no connections (no RS422, ISOBUS or Microwave Module) only LED A will flash trying to communicate. This sequence is typically 3 flashes and then blank.
