1. TROUBLESHOOTING 2-WIRE CONTROLLED IRRIGATION SYSTEMS
INTRODUCTION TO
TROUBLESHOOTING 2-WIRE CONTROLLED IRRIGATION SYSTEMS
A Training Series for Professionals
Copyright © 2014 Armada Technologies LLC

2. Who is Armada Technologies?
Founded in 2004
Based on 40 years in the Test Industry
NOT irrigation professionals! (That means you know more than I do about water and light)
We do know LOTS about Testers.

3. OBJECTIVES
Terminology
Irrigation System Types
Troubleshooting Goals
Tools Available
How to Use the Tools

4. What We Can Use … Electrical Meters Solenoid Activator
Wire & Valve Locators
Ground Fault Finder
Wire Radar
These electrical tools are time-savers. They can turn a day of chasing and digging into an hour of work.

5. Electrical Testing Can Help Answer Common Questions and Requests.
Why is the whole system dead?
Is the controller the problem?
Are there faults in the buried wire?
The controller shows over-current. What is wrong?
Where are the wires buried?
How do we track down problems across a large area?

6. PRODUCTS COMMONLY USED
LOCATING BURIED
WIRING AND VALVES
WATER AND LIGHTING
SYSTEM TEST
& MEASUREMENT
GFL3000
Pro30
Pro400
TROUBLESHOOTING
BURIED WIRING

7. METER SELECTION GUIDE Price General Use Advanced Features
Hi Sensitivity and True RMS reading
For 2-wire irrigation and
LED lighting
True RMS reading
for LED lighting, easy to use
Easy-to-use,
Multi-purpose, clampmeter and multimeter
Pro93
Price
Pro91
Pro90
General Purpose Multimeter
Pro30
General Use
Advanced Features
METER SELECTION GUIDE

8. Check Solenoid Resistance:
TYPICAL USES FOR A METER
Pro30 QUICKer
Check Clock Output: V
Select
Check Solenoid Resistance:
ohms
Select Ω 2
Check AC Power: V
Select V
Check Batteries: V
Select
Armada Technologies

9. TYPICAL USES FOR A METER:
Checking an Irrigation Controller Zone with the Test Probes
CONDITION? RESISTANCE READING
Short circuit 1 – 10 ohms
Open circuit “OL” – Too big to read
Partial Open (Bad Splice) 70 – 150 ohms
Normal solenoid 20 – 60 ohms
VOLTAGE READING
Normal Clock Output 24 – 36 volts

10. Check electrical currents one wire at a time.
Clampmeters can measure electrical current by just closing the spring-loaded jaws over a wire.
This is especially useful in testing lighting systems and 2-wire irrigation systems.
Pro93 ‘Leakage’ Meter
Can read AC currents of
less than 1 mA (milliampere)
Check electrical currents one wire at a time.

11. IRRIGATION SYSTEM TYPES
Multi-wire (Wire-per-valve plus common)
Two-wire (Single control+power)

12. MULTI-WIRE
Clocks or controllers fire valve solenoids that release water into sections of pipe feeding watering zones.
Multi-wire
Controller
Direct Buried Wires, One per Valve
COMMON
COMMON
Valve
Solenoid
Valve
Solenoid
Valve
Solenoid
Watering Zone
Watering Zone
Watering Zone

13. TWO-WIRE
Many newer, long distance, many-valve system designs often use a smart controller, 2-wire data link cable and ‘decoders’ to fire valves.
2-wire
Controller
Two-conductor Gauge Direct Bury Cable
Dual Decoder
Decoder
Decoder
Valve
Solenoids
Valve
Solenoid
Valve
Solenoid

14. DIFFERENCES BETWEEN ELECTRICAL IRRIGATION SYSTEMS
Multi-wire
Wire-per-valve plus a common wire.
24 Vac powering, On/Off control.
Valves can be found with a locator.
Simple waterproof splices can be used.
Cable runs can be 10 feet to 2,000 feet.
Cable depth 12 – 18 inches
Two-wire
Single cable for control+power.
Cable runs can be many 1000s of feet.
Smart controller can help with troubleshooting.
Valves can’t be found with a locator.
Cable depth inches.

15. Conventional Multi-wire vs. Two-Wire Systems
Buried Wiring for
Conventional Multi-wire vs. Two-Wire Systems
‘STAR’ or ‘HOME RUN’
‘DAISY-CHAIN’
Diagrams from Tucor

16. Some Two-wire System Vendors
Tucor
Hunter
Toro
Baseline
Weathermatic
Rainbird

17. In a 2-wire system a single cable can control many valves.
Central
System
2-wire Field
System
003
004
001
002
005
006
007
Valve Boxes
Decoder and Valve
Solenoid
In a 2-wire system a single cable can control many valves.

18. TESTING THE FIELD SYSTEM.

19. TROUBLESHOOTING As with any type of irrigation control system,
start from the source of power and work outward
Controller
Field Wire
Decoders
Valve Solenoids

20. USING ELECTRONIC TESTERS
TO ELIMINATE SUSPECTS
Short
Broken wire
Bad splice
Start by eliminating the controller or water supply as the source of the problem.

21. A Single Two-wire Cable Chains Zone Valves Together for
Power and Control
Courtesy Hunter Industries

22. CHECKING DECODER CONNECTIONS FIND THE WIRE PATH FIND THE WIRE DAMAGE
Pro93
True RMS Clampmeter
FIND THE WIRE
DAMAGE
High Sensitivity
True Power Reading
Type Recommended by Sys Mfgrs
Not Carried by Other Suppliers
Pro800D
Locator
Pro400
TDR Wire Radar
GFL3000
Ground Fault Locator
Good Range
Direct & Antenna Connect
Fast, Precise Damage Location
Measure cable length
Find distance to splices
Spot opens and shorts

23. METER SELECTION GUIDE Price General Use Advanced Features
Hi Sensitivity and True RMS reading
For 2-wire irrigation and
LED lighting
True RMS reading
for LED lighting, easy to use
Easy-to-use,
Multi-purpose, clampmeter and multimeter
Pro93
Price
Pro91
Pro90
General Purpose Multimeter
Pro30
General Use
Advanced Features
METER SELECTION GUIDE

24. Zones apparently not working: Basic Troubleshooting
Controller Powered On
Zones apparently not working: Basic Troubleshooting
Volts to Field Cable OK? N
Troubleshoot Clock AC power, fuse
Operate valves with bleed Y
Disconnect the Field Cable
Check valve solenoid resistance
Troubleshoot Specific Zone Faults
Test Currents/ Leakage at the Control Cable
Excess Main Current?
Excess Current in One Leg?
Low Main Current? N N N Y Y Y
Check for Pair Short or Bad Decoder
Check for Cable Damage or Wet Splice
Check for Break or Open Splice
Locate cable path
Inspect path or use A-Frame
Locate cable path

25. We Are Hunting for Wiring Problems Most of the Time
Bad Decoder:
Lightning blown open or welded short.
Cable Damage:
Cuts, skinned insulation, crushed or stretched wires.
Bad Splice:
Corrosion, exposed metal, damage
Courtesy Hunter Industries

26. Valve Box
Valve
Courtesy Hunter Industries
Decoder
Ground Plate

27. 2-Wire Control Links are Chains of Smart Valve Solenoids Wired in Series, Each Identified by an ID Number
Central
System
Field
System
003
004
001
002
005
006
007
A bad splice or single wire break can take down whole groups of watering zones.

28. IRRIGATION SYSTEM DIAGRAM & NOTES
Tucor Flowmaster
TWC100
TEST EQUIPMENT FOR
GREEN PROFESSIONALS
No Alarms, Manual button flashing
Both Trunks at 31.5 Vacrms
IRRIGATION SYSTEM DIAGRAM & NOTES
TRUNK 1, typical 25 mA
TRUNK 2, typical 6 mA
DATE: 27 May 2014
LOCATION: Fountain Hills, AZ
PROBLEM: Usability of existing buried trunk cables.
NOTES:

29. IRRIGATION SYSTEM DIAGRAM & NOTES
Map the cable routes.
Identify zones and decoders from records.
Note any measurements made like cable resistance.
Note previous mods or repairs.
TEST EQUIPMENT FOR
GREEN PROFESSIONALS
IRRIGATION SYSTEM DIAGRAM & NOTES
DATE:
LOCATION:
PROBLEM:
NOTES:
Do yourself a favor -- take notes and make a sketch of what you find.

30. WIRE TRACKING AND VALVE FINDING.

31. To Begin With, You Need to Know the Route of the Buried Cable and Locations of Valves
2-wire
Controller
Pro800 Hi-Power Locator
Decoder
Decoder
Decoder
Valve
Valve
Valve

32. Locating Buried Cables and Pipes is Part Science, Part Art.
Modern electronics have made it simpler and less expensive.

33. Contractor Price Compact Full Feature $1,000 Hi Power Wire & Valve
$200
$1,000
Contractor
Price
Compact
Full Feature
Pro290
Pro300
Pro871/C
Pro700
Pro800/D
Lighting
Wire & Valve
Hi Power Wire & Valve
Utility

34. The Parts of the Locating Process.
Receiver
Antenna
Ground Stake
Head of Traced Cable
Transmitter

35. Locator Features and Uses
Transmitter Power (range & depth)
Transmitter Frequency (range)
Signal Connection – Direct or Magnetic (cable access)
Receiver Antenna – Peak or Null (spot location)
Depth Measurement (spot location)
PEAK SENSE
Magnetic Field
NULL SENSE
Transmitter
Radiodetection

36. The Ideal Locating Arrangement.
Zone Valve
The Ideal Locating Arrangement.
Establish a Current Loop
Target ‘Zone’ Wire
Both Zone Wires Disconnected At the Controller
Locator Transmitter
Ground Stake

37. Locators find valves (and valve boxes)
by creating large signals at the solenoid.
In 2-wire systems the decoders
block that signal.
LOCATOR
Decoder
Valve
Valve
Zone 1
Zone 2

38. Direct connection to the wire or cable is the best.
Locators put their ‘tag’ signals on by directly connecting to the wires, clamping a transformer jaw around a cable or by broadcasting a field into the ground.
Clamp Method
Broadcast Method
Radiodetection
Direct connection to the wire or cable is the best.

39. Direct connection a wire is best, but there are other ways.
Locators put their ‘tag’ signals on by directly connecting to the wires, or they can use induction - clamping a transformer jaw around a cable or by broadcasting a signal into the ground.
Locator’s Internal Antenna
Pro800D
Inductive Broadcast Method
Direct connection a wire is best, but there are other ways.

40. The broadcast antenna coil is located in the bottom of the case, under the headset and lead storage spot.
The broadcast signal saturates an area for at least 15 feet around the transmitter – it is only possible to trace cables beyond that area.

41. Cable Locating Tips
Size up the situation, look around for signs that will give you clues about cable routes.
Make a sketch of the area and notes on the equipment you see.
Look for locating marks like flags or paint, and be prepared to make your own marks.
Whatever you are told about what is in the ground and where it goes, be skeptical.
Remember as you start to locate that success is 50% science and 50% art (experience).

42. TESTING THE FIELD SYSTEM.

43. The General Process Controller
Controller On - Built-in Diagnostics check
Field wire powered – 30 to 36 volts, or 24 Vac test power unit
Field Wire
First disconnect and check resistance
Each wire to ground greater than 500 kilohm
Across wire pair greater than 100 kilohm
With controller on or in troubleshooting mode
check total powered loop current in each of the 2 wires
Decoders
Locate cable path
Locate valve boxes
Spot check power current passing through the box and going
to the local decoder.
Valve Solenoids
With water on do a manual bleed
Resistance check solenoid 20 – 80 ohms
Use Pro48 tester for solenoid operation check.

44. The Key to Finding Open Circuits or
Shorts is a Sensitive AC Clamp-meter
2-wire
Controller
Toro
Pro93 True RMS
Clamp Meter
Decoder
Decoder
Decoder
Valve
Valve
Valve

45. You Have to Power the Field Cable to Use a Clampmeter
2-wire
Controller
(puts out about 35 V)
Test Power Unit
(puts out about 24 Vac) or
Decoder
Decoder
Decoder
Valve
Valve
Valve

46. You Can Use the Power Unit and Clampmeter to Check for Faults
Test Power Unit
(puts out about 24 Vac)
With the test power connected to the wires the clampmeter around both wires should show zero current.
The current between either wire and ground should be less than 50 mA
Decoder
Decoder
Decoder
Valve
Valve
Valve

47. Zone apparently not working: Basic Troubleshooting
Controller Powered On
Zone apparently not working: Basic Troubleshooting
Volts to Field Cable OK? N
Troubleshoot Clock AC power, fuse
Operate valves with bleed Y
Disconnect the Field Cable
Check valve solenoid resistance
Troubleshoot Specific Zone Faults
Test Currents/ Leakage at the Control Cable
Excess Main Current?
Excess Current in One Leg?
Low Main Current? N N N Y Y Y
Check for Pair Short or Bad Decoder
Check for Cable Damage or Wet Splice
Check for Break or Open Splice
Locate cable path
Inspect path or use A-Frame
Locate cable path

48. Near the Controller, Currents Should Be the Sum of the Decoder Currents
1 to 10 mA
each

49. Measuring Points in a Valve Box
Pro93 Clamp-meter
Measuring Points in a Valve Box A B C
A: Valve resistance
B: Main power In
C: Decoder power
D: Main power Out D
Checking electrical power flow and cable continuity means measuring electrical currents.

50. When a Zone is Activated, Total Current Should Be the Sum of the Decoder Currents Plus one Solenoid (about 200 mA)

51. FINDING NICKS AND CUTS IN BURIED WIRES.

52. Finding a Break or a Nick in the Insulation.
The GFL3000 A-Frame isolates breaks in buried cable insulation.
Radiodetection

53. Once you know the path of the target cable, you can use the tracking pulses from the GFL3000 to find the damaged spot.

54. Moving across the wire path to center the needle will bring you to within a shovel width of the damage.

55. CHECK DISTANCES & FIND WIRE DAMAGE
Pro400
TDR “Wire Radar”
Measure cable length
Find distance to splices
Spot opens and shorts
Example display: A valve solenoid 100 feet down the cable with a splice at 75 feet.

56. The Pro400 “Wire Radar” Examples
The key information appears in this area.
Short circuit 50 feet down the cable.
Cable open at 100 feet, splice visible at 75 feet.
Once the cable correction factor ‘Vp’ is set, you can read distances down the cable by moving the cursor

57. Demo Videos are on DVD and can Be Seen at www.armadatech.com

58. Armada Technologies on the Internet of Things
Main web site training videos
The Armada YouTube Channel for Videos
Armada on Facebook
Armada blog with downloadable application notes

59. Questions.

60. Splices are the weakest link in the field system.
TYPICAL 2-WIRE VALVE BOX
Water Supply
Hunter
Super Splices
Watering Zone
2-wire Data+Power
Decoder
Valve Solenoid
Splices are the weakest link in the field system.