DICKEY-john TRAINING CONFERENCE HANDBOOK Programming, Operating & Basic Repair Techniques CCS100 Control System CMS100 Monitoring System 1
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Table of Contents Course Objectives...7 Lesson Materials...9 Basic Functions of CCS/CMS Systems...11 Overview of System Layout... 13 Basic Modes of Operation... 19 Developing Constants Granular System... 29 Developing Constants Liquid System... 33 Developing Constants Anhydrous Ammonia... 41 Technical Reference Material... 47 Commonly Asked Questions... 59 Granular Spreader Constant References... 67 Liquid Sprayer Constant References... 68 Anhydrous Ammonia Constant References... 69 Cable Repair Procedures... 70 Troubleshooting Sensors... 74 3
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WELCOME DICKEY-john welcomes the opportunity to present this material. It is our pleasure to provide training on this equipment and to answer any concerns or questions. With this exchange of information, we can together perform our jobs better. The main function of this workshop is to allow you to become more acquainted with these products. It is always a pleasure to serve you our valued customers. DICKEY-john believes that the more understanding its customer s have of a product, the more useful that product becomes. 5
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Course Objectives The CCS/CMS100 system is an extremely versatile unit that can be easily programmed to automatically control the application rates of given products regardless of changes in vehicle ground speed and also monitor a number of fi eld conditions. The major purpose of this course is to train you in the operation, programming, and the performing of minor troubleshooting procedures on the CCS/CMS100 Control system. When you have completed this course, you will have learned how to: Explain the basic function and use of each system. Explain the differences between and the functions of both units. Defi ne sensors required and explain the purpose of each. Defi ne the use of each touchswitch on the front panel. Enter the different modes and explain the function of each. Read and explain the meanings of displayed data. State the meaning of error messages and how to correct errors. Understand how to use the cabling diagrams. Perform basic repair by using simple troubleshooting charts. Secure aid in the event of a serious problem. 7
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Lesson Materials PART 1 This manual is divided into two separate parts. Part I contains instructional materials to explain basic overall concepts and operating principles of the systems. Part II contains more detailed reference materials which elaborate certain subjects with more in-depth information. Other information is for reference material use later. Topics included in this Part are: Lesson 1: Lesson 2: Lesson 3: Lesson 4: Lesson 5: Lesson 6: Lesson 7: Basic Function of CCS/CMS Systems. Overview of System Layout. Basic Modes of Operation. Developing Constants Granular System. Developing Constants Liquid System. Developing Constants Anhydrous Ammonia. Common Operator Problems Encountered. 9
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Basic Functions of CCS/CMS Systems LESSON 1 The CCS and CMS units are often connected together into one control system. Sensors develop status signals which are delivered through cabling to the two consoles for processing and monitoring. Output drive signals from the CCS100 control the application rate of the product. Input signals to the CMS100 monitor operating conditions. In this lesson, you will learn how to: Defi ne the basic function of the CCS unit. Defi ne the basic function of the CMS unit. Use both units together in one system Confi gure a basic granular spreader control system. Confi gure a liquid sprayer control system. Confi gure an anhydrous ammonia control system. Topics: 1. Overall System Function 2. Sensors Required and Options Available 3. System Confi gurations The CCS100 and CMS100 consoles units are both microprocessor controlled containing similar circuitry but performing different functions. The major difference between the units is designed into the internal program of the microprocessor. The operator must complete the programming process in the fi eld by entering a few constants upon which the microprocessor acts to calculate its performance. Once the two units are properly programmed, the system (both units) automatically controls (CCS100) the application rate of the product and also monitors (CMS100) speed and area information. Automatic application starts when the vehicle begins to move, varies as ground speed changes and stops when the vehicle ceases moving. The product application rate is controlled as long as the ground speed is within the specifi ed speed range of the system. Function of the CCS Console The CCS100 Custom Control System is a versatile device that can be installed as either a granular spreader, NH3 or liquid system. It can then be programmed to automatically control the application rate of a given product. That rate of application remains constant throughout the fi eld regardless of any changes in the vehicle ground speed. Function of the CMS Console The CMS100 Custom Monitoring System is a monitoring device that is usually installed as a companion unit to the CCS100 system for displaying additional information. The unit utilizes the same sensor signals as the CCS100 console to develop status readouts. The additional information displayed is for ground speed, fi eld area, total area, area per hour, distance (footage counter), fi eld product, total product, product level, application rate, product sensor output, and an auxiliary sensor output. The CMS100 unit normally connects to a control system s sensors through an addition of a Y cable which parallels the sensor input signals. The CMS100 also can operate as a stand alone unit to monitor speed/area functions provided the CCS100 main harness and ground speed sensor are installed on the vehicle. The CMS100 console can be used alone to monitor speed/area provided the harness and sensors are available. Three Basic Configurations The two console units are installed in one of three basic confi gurations. The CMS100 unit is connected to each system via a Y-cable. 11
Putting It Together: The CCS100 console controls the application rate and the CMS100 console monitors speed/area functions. The two consoles use signals from the same sensors and are connected in parallel to share those signals. The CCS100 console can be used interchangeably between a liquid sprayer system and an anhydrous ammonia system by changing one constant location. 1. A Granular Spreader Control System consists of fi ve major components; (1) control console(s) with a switch module, (2) a hydraulic control valve and vale driver, (3) a ground speed sensor, (4) an application rate sensor, and (5) an optional hopper level sensor or fan sensor. The two consoles are installed within the vehicle cab. The hydraulic control vale is installed in the hydraulic line to the conveyor motor to regulate the motor rate. The ground speed sensor senses the miles per hour (MPH) speed of the vehicle. One of three types of ground speed sensors is installed; (1) in-line speedometer drive sensor, (2) magnetic wheel sensor, or (3) radar velocity sensor. The application rate sensor is installed on a shaft that rotates at a proportional rate to the conveyor speed. 2. A Liquid Sprayer Control System consists of only four major components; (1) control console(s) with a switch module, (2) liquid control valve, (3) ground speed sensor, and (4) a pressure sensor. The CCS100 console compares these input signals to a desired application rate as programmed by the operator and develops a proper output drive signal to the servo control valve to maintain uniform application rate. 3. An Anhydrous Ammonia Control System consists of fi ve major components; (1) control console(s) with a switch module, (2) control valve, (3) fl ow-meter, (4) thermal transfer unit(s), and (5) a ground speed sensor. A vapor detector and implement switch may also be used. When installed on an Anhydrous Ammonia Applicator, the fl ow of the product varies automatically in proportion to ground speed changes, keeping the application rate uniform throughout the fi eld. Basic Cabling Harnesses The CCS100 and CMS100 consoles are connected to the required group of sensors through cabling harnesses. These harnesses deliver the sensor input signals to the consoles as well as return drive signals for controlling the application rate of the product. Several different sets of harnesses are employed depending upon the type of vehicle and the confi guration of the system involved (See Lesson 2). 12
Overview of System Layout Lesson 2 The CCS100 and CMS100 units are connected to their sensors through cabling. The cables used and the number of sensors required are determined by the system specifi cations and the vehicle on which the system is installed. Topics: 1. Harness Functions 2. Granular System Harness Layout 3. Liquid System Harness Layout 4. CMS100 Confi gurations 5. Extension Cable Use Harness Configurations In order to meet the needs of a number of applications and to remain versatile, a number of harnesses and extensions are available. Variations to any of these harness arrangements are made by adding extension cables to reach extended lengths. Also, three truck harness are available for use when only the CMS100 console is installed. In this lesson, you will learn how to: Select cabling for a granular spreader system. Select cabling for a liquid sprayer system. Select cabling for an anhydrous ammonia system. Select cabling for specifi c CMS100 applications. 13
Typical Granular System Configuration Hydraulic Control Valve Valve Actuator Driver Module Application Rate Sensor Pressure Transducer Connector Harness Extension Hopper Level Sensor Hopper Level Sensor o o Fan RPM Sensor 14
Typical Liquid System Configuration for Pull Type Sprayer Extension Cable Implement Harness Extension Cable Valve Actuator Driver Module Extension Cable Pressure Transducer 15
Liquid System with Truck Harness Configuration Extension Cable Pressure Transducer Valve Actuator Driver Module Extension Cable 16
Typical Anhydrous Ammonia System Configuration Hardware Kit Thermal Transfer Unit Extension Cable Implement Harness Valve Actuator Driver Module Extension Cable Flow Meter Vapor Detector 17
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Basic Modes of Operation LESSON 3 When power is applied to the system, both the CCS100 and CMS100 units come up in the OPERATE mode ready to go. The OPERATE mode of the system is discussed in the lesson and the SETUP mode to enter constants is discussed in the next lesson. In this lesson, you will learn how to: Turn power on to both the CCS100 and the CMS100 console units. Use the Switch Module. Defi ne the function of the Basic OPERATE mode for both units. Defi ne the function of the Basic SETUP mode for both units. Defi ne the purpose of the constants for both the CCS100 and the CMS100. Enter Constants into the memory of both units. Topics: Similarity Between CCS100 and CMS100 Units Use of the Switch Module Applying Power Defi ning and Using the OPERATE Mode Defi ning and Using the SETUP Mode Defi nition of All Switches Meaning of Display Panel Messages Console Similarities Both the CCS100 and CMS100 are very similar in appearance and basic operation. Each unit has its own power switch, located to the right side, an LCD display for reading data, and three touchswitches to select and control the various functions of the system. Both the CCS100 and CMS100 consoles employ two basic modes of operations OPERATE and SETUP. These two modes are controlled by the three touchswitches across the lower portion of the console front. Each touchswitch contains two legends. The supper legend identifi es the OPERATE mode and the lower legend identifi es the SETUP mode. The OPERATE mode selects normal fi eld operation and the SETUP mode allows for entering constants into memory which actually control the desired rate of product application. If you are familiarizing yourself for the fi rst time on installed equipment, simply make sure no product is loaded into the tank or hopper. Turning On System Power To turn power onto the system, switch the power switch to the ON position on the front (right side) of each console. Whenever power is turned on, both consoles come up in the OPERATE mode, ready to go. It is important to note that the CMS100 also receives power through the vehicle ignition switch. If either the power switch or the ignition switch is off, the display indicates OFF. Operating the System Each time power is applied through the ignition switch and the power switch to each console, the alarm sounds briefl y and each display shows all display segments for approximately one second. For the next second, the programmed value for the application rate is displayed. If the CCS100 is in the P mode, the high and low speed and pressure ranges are also displayed. Following this, the CCS100 enters the OPERATE mode and displays the current application rate which remains zero until the vehicle begins to move to produce a ground speed. If the display on the CCS100 should show OFF, the OFF/AUTO/FLUSH switch on the switch module is in the AUTO position. Simply change it to OFF. The CMS100 also enters it s OPERATE mode. If the display on the CMS100 shows OFF, either the power switch or the ignition switch is not turned on. 19
Using the CCS100 Console in the OPERATE Mode Once in the OPERATE mode, the display indicates pounds (or gallons for liquid system) per acre. The OPERATE mode touchswitches for + and - increase or decrease the application rate by a specifi ed increment as programmed into memory. Anytime the application rate increments from the targeted rate, the displayed value per acre fl ashes. If either the + or - touchswitches are depressed to change the application rate, the displayed value begins to fl ash. To return to the target application rate, depress the OPER touchswitch and the display stops fl ashing. Also note each valid touchswitch closure initiates a short tone burst from the alarm. Using the Switch Module The switch module functions in conjunction with the CCS100 console to control the product output of the system. A three position switch on the switch module overrides the output commands of the CCS100 unit. The OFF position provides a control valve shut-off command to the control console. The AUTO position allows the console automatic control of the system. In this position, the application rate is controlled by the ground speed. When the switch is held in the FLUSH position (spring loaded), the control valve is driven open to a predetermined fl ow rate. This action purges the system. In the SETUP mode, the switch module switch performs no function. CCS100 Console with Switch Module Using the CMS100 Console in the Operate Mode Once in the OPERATE mode, a triangular shaped pointer near the upper or lower edge of the display points to the monitored function. The function s current value is shown by the 6-digit display. Depressing the center touchswitch moves the pointer to the right. The current value for each monitored function is indicated on the display. By repeat edly depressing the center touchswitch (right pointing arrow), the pointer travels from left to right across the digital display. The left touchswitch (left pointing arrow) performs the same function except in reverse order. 20 The right touchswitch (RESET) resets the following functions to zero when selected; (1) Field Area, (2) Total Area, (3) Field Product, (4) Total Product. It also serves to initialize or set Product Level to the programmed tank (or hopper) level full value. To reset, depress and hold the RESET touchswitch for approximately three seconds.
CMS100 Console Up to eleven functions are monitored by the CMS100 unit. Defi nitions for these functions are outlined below. SPEED Vehicle ground speed in MPH (kph). FIELD AREA Accumulated area in acres (hectares) the vehicle has covered since the last reset. This function keeps a daily record of the area covered. Up to 999999 acres (hectares) can be accumulated before the counter rolls over to zero. If the optional CCS100 implement switch is installed, accumulation occurs only when the spreader is engaged. When the switch module is in the OFF position, accumulation is also stopped. When the accumulation is inhibited, the check mark, on the lower left edge of the display, is displayed. Accumulated data is retained in memory when the console is turned off. TOTAL AREA Total accumulated area in acres (hectares) the vehicle has covered since the counter was last reset. This function operates the same as for Field Area above. AREA/HR Displays acres (hectares) per hour. DISTANCE Displays distance traveled in feet (or meters) the vehicle has traveled between the counter start and stop cycle. Up to 999999 feet (meters) can be accumulated before the counter rolls over to zero. The counter can be started and stopped by momentarily depressing the RESET touchswitch. Holding the RESET touchswitch depressed for approximately 3 second will reset the counter to zero. FIELD PRODUCT Displays the accumulated pounds (kilograms) or gallons applied. This function is useful in keeping record of the amount of product applied per fi eld or per day. TOTAL PRODUCT Displays accumulated pounds (kilograms) or gallons applied. This function may keep a record of the total amount of product applied per season (year) up to 999999 pounds (kilograms). PRODUCT LEVEL Displays the pounds (kilograms) for granular or NH3 system 21
or gallons (liters) for liquid system of product remaining. Each time the hopper or tank is fi lled, the Product Level must be reset to the value of the programmed constant. APPL RATE Displays CCS to direct the operator to the CCS100 console for the application rate. PRODUCT SENSOR Displays the RPM of a 360 slot application rate sensor input shaft when used on a granular system. If used on a liquid system or a NH3 system, the output of the pressure transducer or fl ow meter is displayed. When the CMS100 is used on a granular system with the CCS100, the display normally shows zero (no sensor input). On a sprayer control system, the display indicates pressure at the pressure transducer in psi (bars). On anhydrous ammonia applicator control, the display shows the frequency output of the fl ow meter. Auxiliary SENSOR Displays the output of an auxiliary sensor, such as fan RPM on a fl ow based granular system. When used with the CCS100 Sprayer Control System (pressure based), this display is skipped. For a CCS100 Anhydrous Ammonia Applicator Control System (fl ow based), this display normally shows a zero (no sensor input). APPLICATION RATE SENSOR REVOLUTION COUNTER The Console can be programmed to count 360 output cycles per revolution application rate sensor when installed on the conveyor drive shaft. The PRODUCT (Field and Total) readouts accumulate and display the counted revolutions. To count application rate sensor revolutions, proceed as follows: 1. 2. 3. 4. Enter the SETUP Mode Set DENSITY Constant (location C1) to.2778. Set SPREADER Constant (location CZ) to.0579. Return to the OPERATE Mode. The PRODUCT Readouts (Field and Total) displays application rate sensor revolutions. To reset the PRODUCT readouts to zero, depress and hold the RESET touchswitch for approximately 3 seconds. IMPORTANT: Steps 1 through 4 are for a 360 output cycles per revolution Application Rate Sensor installed on the Conveyor Drive Shaft. 0350 If the Application Rate Sensor is installed at a location other than the Conveyor Drive Shaft the Density Constant (C1) value to be used must be determined as follows: DENSITY CONSTANT = 100 (GEAR RATIO) Number of Sensor Output Cycles Per Rev. Where: GEAR RATIO = CONVEYOR DRIVE SHAFT REV. APP RATE SENSOR SHAFT REV. Entering the Setup Mode In order for either the CCS100 console or the CMS100 console to make cor 22
rect calculations, certain constants must be placed into the memory of each unit. These constants are known values for the specifi c system being used and are necessary for the microprocessor to calculate accurately from the signals received by the system sensors. In the next lesson details of how constants are obtained is discussed. It is very important that you understand the defi nition of each constant and how the value of each is determined at that time. Once understood and the correct values are obtained, programming the constants becomes a simple matter. Entering Constants into the CCS100 Memory After power is applied to the system, both the CCS100 and CMS100 units come up in the OPERATE mode. To enter the SETUP mode, simply depress and hold the OPER/SETUP touchswitch for approximately three seconds. The SETUP mode is entered when the word message SETUP in the upper right hand corner of the display begins fl ashing and a single bargraph segment (pointer) appears under the A of the setup scale. 1. 2. 3. Refer to the Constants Decal located on the top of the console. The two Decals illustrated in the left column on the next page are for explanation purposes only and probably differ signifi cantly from the one on your system. You must use the decal on your system when entering constants in order to match the SETUP POS. (pointer location) to the CONSTANTS description. The Constants Decal consists of basic two columns SETUP POS and CONSTANTS. The SETUP POS column shows a letter to denote the position of the pointer (bargraph segment) on the setup scale and the CON- STANTS column shows the name of the constant to be entered. With the setup pointer under the A position for a liquid sprayer or anhydrous ammonia system, the display indicates P, Pn, or F. Depress the right touchswitch (0-9) and note the display increments through those three letters. If your system is a liquid sprayer, leave it in the P position. If it is an ammonia system, leave it in the F position. If your system is either a sprayer or anhydrous ammonia, increment to the B position, APPLICATION RATE, by depressing the OPER/SETUP touchswitch. Proceed to Step 4. SAMPLE DECAL FOR SPRAYER/ANHYDROUS AMMONIA SYSTEMS SPRAYER ANHYDROUS AMMONIA SET- UP POS. CONSTANTS SET- UP POS. CONSTANTS A P or Pn A F B APPLICATION RATE B APPLICATION RATE C APPLICATION RATE +/- C APPLICATION RATE +/- D NOZZLE SPACING D IMPLEMENT WIDTH E NOZZLE CAPACITY PRESSURE E DENSITY F NOZZLE FLOW CAPACITY F FLOW SENSOR CONSTANT G FLUSH PRESSURE G FLUSH FLOW RATE ( 10) 23
H CONVERSION FACTOR H BARGRAPH MAX. FLOW RATE (-10) I ZERO PRESSURE CALIBRATION I SYSTEM RESPONSE J SYSTEM RESPONSE J GROUND SPEED CALIBRATION A NOZZLE MONITOR SET B GROUND SPEED CALIBRATION C PRESSURE LIMITS SET 4. With the setup pointer under the A position for a granular spreader system or B position for liquid or ammonia systems, the display shows a four digit number representing the existing programmed APPLICATION RATE. The left most digit should be fl ashing. Depress the center (left/right character) touchswitch and note that the digit to the right of the left most digit begins to fl ash. Repeatedly depress and release the center touchswitch and note the fl ashing digit moves from left to right across the display. The fl ashing digit indicates the one that changes if the right (0-9) touchswitch is depressed. Depressing the right (0-9) touchswitch causes the fl ashing digit to increase value by one count. Repeatedly depressing and releasing the touchswitch causes the fl ashing digit to sequence from digits 0 (zero) through 9 (nine). Depress and hold the center (left/right character) touchswitch and the decimal point sequences from right to left. When the decimal point is not shown on the display the four digits represent a whole number. The actual value of the constant depends on the placement of the decimal point. SAMPLE DECAL FOR GRANULAR SPREADER SETUP POS. CONSTANTS A APPLICATION RATE B APPLICATION RATE +/- C SPREAD WIDTH D DENSITY E SPREADER CONSTANT F SPREADER FLUSH FLOW RATE G BARGRAPH MAXIMUM FLOW H SYSTEM RESPONSE I GROUND SPEED CALIBRATION 24
5. 1. The above basic procedure sets individual digits and decimal point so the desired value of the four digit constant is entered into memory and displayed on the readout. The remaining constants are entered in the same fashion. To familiarize yourself with the constant locations, repeatedly depress the OPER touchswitch while referring to your systems Constants Decal. Note that the cursor increments to each SETUP POS shown on the Decal. Also note that if the SETUP POS exceeds J (anhydrous and liquid systems) the pointer returns to the A position, reverses (inverts) and becomes the segment that is turned off instead of the segment that is turned on. This is noted on the decal by inverted (white) type. When fi rst entering the GROUND SPEED CALIBRATION location (as shown on the Decal) the display shows four digits with one digit fl ashing. This location is used to manually enter a known constant or an average of several calibration procedures. Depressing the OPER touchswitch, causes all four digits to fl ash. This location is used to perform the Ground Speed Calibration procedures as described in the CONSTANTS lesson later. After reaching the last constant shown on the decal, depressing the OPER touchswitch returns to the fi rst constant location (pointer under SETUP POS. A). Each constant location can be displayed in sequence again and again by continually depressing the OPER touchswitch. This cycle can continue until the SETUP mode is exited by depressing holding the OPER touchswitch for approximately 3 seconds. Entering Constants into the CMS100 Memory Entering the SETUP mode on the CMS100 is very similar as to the CCS100. Whenever power is applied to the system, the CMS100 unit comes up in the OP- ERATE mode. Remember, both the ignition and power switch must be turned on for the unit to operate. After power is on, the SETUP mode is entered by depressing and holding SETUP touchswitch (left touchswitch) for approximately three seconds. The SETUP mode is entered as soon as the two left digits showing C0 or C1 and the colon begin fl ashing. If neither the C0 or C1 is displayed, refer to the Constants Decal supplied with the unit. AREA SPEED FIELD TOTAL /HR DISTANCE C 1 1. 0 0 0 ON FIELD TOTAL LEVEL PRODUCT SETUP DISPLAY DICKEY-john R APPL RATE PRODUCT AUX SENSOR RESET 9 0 OFF DjCMS100 25
1. 2. 3. Refer to the Constants Decal located on the top of the console. The Constants Decal illustrated below is for explanation purposes only and may differ signifi cantly from the one on your system. You must use the decal on your system when entering constants in order to match the SETUP POS. (pointer location) to the CONSTANTS description. If your system is a granular spreader, go to step 5. If C0 is displayed and fl ashing on the left two digits of the display, an F, P, or FF should be shown on the right. Depress the right touchswitch (0-9) several times and note the display increments through F, P, and FF. Refer to the Constants Decal and notice that the SETUP NO. C0 in the SPRAYER CONSTANTS column shows P and the ANHYDROUS AMMO- NIA CONSTANTS column shows F. When P is selected, the SETUP NO. and CONSTANTS to be entered are shown in the Sprayer Column. The FF is not used. SPRAYER ANHYDROUS AMMONIA SETUP NO. CONSTANTS SETUP NO. CONSTANTS C0 P C0 F C1 CONVERSION FACTOR C1 DENSITY C2 SUM OF NOZZLE CAPACITIES C2 FLOW SENSOR CONSTANT C4 NOZZLE CAPACITY PRESSURE C6 TANK LEVEL-FULL ( 10) C5 PRESSURE SENSOR OFFSET C7 TANK ALARM LEVEL ( 10) C6 TANK LEVEL-FULL ( 10) U2 VOLUME UNITS CONSTANT C7 TANK ALARM LEVEL ( 10) U6 GROUND SPEED CALIBRATION U2 VOLUME UNITS CONSTANT E0 APPLICATOR SWITCH SENSE U6 GROUND SPEED CALIBRATION E1 APPLICATOR SECTION 1 E0 BOOM SWITCH SENSE E2 APPLICATOR SECTION 2 E1 BOOM SECTION 1 E3 APPLICATOR SECTION 3 E2 BOOM SECTION 2 E4 APPLICATOR SECTION 4 E3 BOOM SECTION 3 E5 APPLICATOR SECTION 5 E4 BOOM SECTION 4 E6 APPLICATOR SECTION 6 E5 BOOM SECTION 5 E6 BOOM SECTION 6 SETUP POS. C1 C2 C6 C7 C8 U6 E1 E2 E3 L0 L1 GRANULAR SPREADER CONSTANTS PRODUCT DENSITY SPREADER CONSTANT HOPPER LEVEL - FULL HOPPER ALARM LEVEL FAN SENSOR CONSTANT GROUND SPEED CALIBRATION SPREAD WIDTH A SPREAD WIDTH B SPREAD WIDTH C FAN LOW SPEED LIMIT FAN HIGH SPEED LIMIT 26
4. 5. 6. Press the SETUP touchswitch (left side) and note the left two digits increment to C1. The right four digits contain the current value with the most signifi cant digit fl ashing. With C1 displayed, depress the center touchswitch and note that the digit to the right of the most signifi cant digit begins to fl ash. Repeatedly depress and release the center (left/right character) touchswitch and note that the fl ashing digit moves from left to right across the display. The fl ashing digit indicates to the operator the digit that changes when the right touchswitch (0-9) is depressed. Depress the touchswitch and the fl ashing digit increases value by one count. Repeatedly depress and release the right touchswitch and note that the fl ashing digit sequences digits 0 (zero) through 9 (nine). The value of the digit is as shown on the display. Depress and hold the center (left/right character) touchswitch and the decimal point sequences from right to left. When the decimal point is not shown, the 4 digits comprise a whole number. The value of the constant depends on the placement of the decimal point. To familiarize yourself with the locations of the constants, repeatedly depress the SETUP (left) touchswitch and while referring to your systems Constants Decal, note that the left 2 digits of the display shows the SETUP NO. Putting it together: Both the CCS100 and the CMS100 have two basic modes OPERATE and SETUP OPERATE Mode Used for field operation SETUP Mode Used to enter constants for the microprocessor to calculate upon. Note that when you fi rst enter U6 GROUND SPEED CAL Location (as shown on the display) the right 4 digits show the constants current value with the most signifi cant digit fl ashing. This location is used to enter a known constant or an average of several calibration procedures. Depress the SETUP touchswitch, the right 4 digits all begin to fl ash. This location is used when performing the Ground Speed Calibration procedure. When reaching the last constant location as shown on the Constant Decal, depressing the SETUP touchswitch results in the fi rst constant location being displayed. Each constant location can be displayed in sequence again and again by depressing the SETUP touchswitch. This cycle continues until the SETUP Mode is exited by depressing and holding the SETUP touchswitch for approximately 3 seconds. 27
Common Operator Problems The following is a list of commonly encountered problems. Until you become familiar with the basic functions of the CCS and CMS, small problems can be very disturbing. A little time spent now to understand a few simple oversights can minimize frustrations later. In this lesson, you will learn how to: Recognize basic faults and oversight. Correct basic problems. Know when the problem is beyond a simple solution. Console won t turn on. Bad fuse or no battery voltage. Check the fuse fi rst and then the battery voltage to the unit. Battery terminal corrosion may be the cause. Console reads OFF Switch module switch is in the AUTO position when console was powered up. Change the switch to OFF position. Switch module unplugged from harness. Console left in AUTO with no ground speed signal seen after 60 seconds. Console went from the SETUP mode to OPERATE mode with switch in the AUTO position. Alarm sounds continuously/fragmented Display Segments Battery voltage low (below 8.5V). SET UP on the console display is flashing Console is in setup mode. To get to OPERATE mode, depress and hold OPER/SETUP touchswitch until the SETUP message turns off (approximately 3 seconds). Alarm sounds (Beeps) Normal alarm condition for application error (Valve wide open). Switch module is in the AUTO or FLUSH position and control valve is wide open. Check shaft speed sensor. Display shows APER Console doesn t see fast enough shaft speed for the speed you are driving. Change speed and also check the hydraulic oil fl ow. System won t run in AUTO Vehicle must be moving for the system to run in AUTO. Check to see if it runs in FLUSH. Alarm beeps and display shows APER Control valve is wide open whenever APER message is displayed. Blockage is caused by something other than the system or control valve. Manual or electric valves closed. Tank empty or faulty pump. Display shows.0 and bargraph area is blank No or very low ground speed for programmed application rate. Possible bad speed sensor or speed sensor setup position I (90o). 28
Developing Constants Granular System LESSON 4 The console requires constants (fi xed numbers) to accurately compute displayed information and to control the application rate of the product. It is very important to understand what constants are required and how to arrive at the correct numbers (constants) for programming (entering into memory) the console. In this lesson, you will learn how to: Defi ne a constant for both the CCS100 and the CMS100 console units. Determine accurate values to enter into memory. Constants are entered into the Setup Mode Memory locations of the CCS100 to describe the vehicle capabilities to the control console. The console uses these values (numbers) to accurately compute the application rate of the product. It is therefore very important that you understand what constants are required and how to arrive at the correct numbers (constants) for programming (entering into memory) the console. When entering numbers, the decimal point can always be positioned as desired. Determining CCS100 Constants Application Rate The application rate is the volume of product to be applied per unit of area; pounds per acre (kilograms per hectare). The amount must be within the delivery capabilities of your System. Application Rate +/- (change-on-the-go) This value allows the operator the option of increasing or decreasing the application rate by a specifi ed amount, while moving through the fi eld. This value is the desired increment of change in pounds per acre (kilograms per hectare). SPREAD WIDTH The spread width constant is the width of the spread pattern in feet (meters). DENSITY The density constant is the product weight in pounds (kilograms) per cubic foot (liter). SPREADER CONSTANT The spreader constant instructs the console the volume of material for discharging from the spreader at a particular feed gate setting. It is a ratio between the amount of material discharged through the gate and the application rate sensor output (cycles per cubic inch). Each feed gate setting must have its own spreader constant. If the Spreader Discharge Factor (SDF) is supplied by the spreader manufacturer in cubic feet per conveyor drive shaft revolution for each gate setting, the spreader constant can be determined using the following formula: Spreader Constant = (.2038) (Gear Ratio) SDF Where: Gear Ratio is the ratio between the sensor shaft revolutions and the conveyor drive shaft revolutions. The spreader constant for each gate height setting must be calculated. Spreader Flush Flow Rate This constant establishes the rate in pounds (kilograms) per hour the material discharge rate the spreader attains when the OFF/AUTO/FLUSH switch is held in the FLUSH position. The desired value must be divided by ten before entering into memory. Example: The factory entered value is 3000 which means the FLUSH discharge rate is 30,000 pounds (kilograms) per hour. 29
Bargraph Maximum Flow This constant sets the full scale value of the bargraph display. The units are pounds (kilograms) per hour. A recommended value is two times the normal pounds (kilograms) per hour output resulting in the bargraph functioning at mid-range. The normal fl ow rate value is calculated as follows: For U.S. Fr= (APR)(MPH)(W)(.1212) Where: Fr = Flow rate in lbs/hr APR = Application Rate in lbs/acre MPH = Miles per hour W = Spread pattern width in feet For Metric Fr= (APR)(KPH)(W)(.1212) Where: Fr = Flow rate in Kg/hr APR = Application Rate in Kg/hectare KPH = Kilometers per hour W = Spread pattern width in meters 1. 2. After the number is determined, multiply the calculated normal fl ow rate times two and then round off the results to nearest thousand. The fi nal value to be entered into memory must be divided by 10. System Response This number affects the control valve response time as well as the steady operation accuracy. When set correctly, the control system responds to a change in ground speed by repositioning the control valve with a slight overshoot and without causing oscillation around the new product fl ow rate. The System Response Constant is factory set to 3.0 as a beginning point. During fi eld operation, if one of the following symptoms is observed the value should be changed in the direction described. If the console display fl uctuates above and below the targeted application rate by a large amount (10% to 20%), this indicates that the System Response Constant is too large and should be decreased in value (see Note below). If the console display is slow in responding to a change in ground speed or application rate (change-on-the-go) or it stabilizes at some indication other than the targeted application rate, this indicates that the System Response Constant is too small and should be increased in value (see Note below). NOTE: Change the value by.5 count in the indicated direction. Repeat procedure until the control system operates to satisfaction. For fi ne tuning, values in.1 (tenths) may be entered. For example, 2.5 rather than 2 or 3. GROUND SPEED CALIBRATION This constant is a number that matches the ground speed sensor to the control console. To obtain the correct constant, the vehicle is driven over a measured course while performing the following procedure. IMPORTANT: The ground speed calibration constant has two entry methods: (1) manually entering a known value and (2) performing the calibration procedure. The manual entry location is the fi rst entered when the pointer increments to SETUP POS. I and is identifi ed by a single digit fl ashing. This entry method is 30
used to enter an average that is obtained by performing the calibration procedure several times. Averaging of the calibration procedure numbers enhances the accuracy of the vehicle ground speed. Touching the SETUP switch advances to the second method and it is identifi ed by all four digits fl ashing on the display. The ground speed calibration constant is determined as follows: 1. 2. 3. 4. 5. 6. Measure a 400 ft. (122 meter) infi eld course (preferably on level ground). Mark the start and fi nish points so the course is plainly visible from the cab as you drive past. System must be in SETUP mode with the pointer in the second ground speed calibration position (all digits fl ashing). Drive up to the start of marked course at a slow (minimum of 2 mph) (km/h) operating speed. When even with the start marker, touch the center - (minus) touchswitch. The display readout should go to 0 (zero) then start counting up as you are moving. Continue to drive the measured course at a constant speed. When even with the fi nish marker, touch the center - (minus) touchswitch again. The Ground Speed Calibration number will be displayed on the console s readout. Record this number for future reference. IMPORTANT: It is recommended that the above ground speed calibration procedure be repeated 3 or 4 times and the displayed numbers averaged. Enter the resulting average in console memory using the manual entry method. Determining CMS100 Constants These constants must be entered into the memory locations of the CMS100 so that accurate computations regarding area and product accumulations can be made. Some of the constant values are the same as used in the CCS100 console. C1. PRODUCT DENSITY This constant is the product weight in pounds (kilograms) per cubic foot (liter). Same as entered for the CCS100 DNEISTY Constant Setup Position. C2. SPREADER CONSTANT This is a number that tells the console the volume of material that is discharged from the spreader at a particular feed gate setting. It is the ratio between the amount of material discharged through the gate and the application rate sensor output (cycles per cubic inch). Each feed gate setting must have its own spreader constant. This constant value is the same as entered in the CCS100 Spreader Constant Setup Position. C6. HOPPER LEVEL-FULL This constant is the total number of pounds (kilograms) contained in the spreader hopper divided by 10 (ten). Example: If your hopper contained 4000 pounds (kilograms), your Hopper Level-Full constant would be 400. 31
C7. HOPPER ALARM LEVEL This constant is the hopper level at which the alarm sounds divided by 10 (ten). Example: If you desire an alarm with 500 pounds (kilograms) left in the hopper, you Hopper Alarm Level constant would be 50. To disable the alarm, set this constant to 0000. C8. FAN SENSOR CONSTANT This constant is a number that tells the console the number of sensor cycles per revolution of the sensed shaft. FAN SENSOR CONSTANT = 60 Number of sensed points Where: Number of sensed points = The number of Magnet pole pairs, Gear teeth, or Bolt Heads per shaft revolution. U6. GROUND SPEED CALIBRATION This matches the ground speed sensor to the console and is the same value as the CCS100 constant. E1 through E3. SPREAD WIDTH A, B and C The spread width constants give the monitoring system the capabilities of accumulating area depending on the number of active spreader booms. If your Spreader is not divided in sections, enter the spread width in feet (meters) in E1. If your spreader has more than one section, enter each section spread width in feet or meters beginning with E1. All unused spread width constants must be set to 0000. L0. FAN LOW SPEED LIMIT This constant is the RPM at which an alarm is desired if the sensed fan slows down. L1. FAN HIGH SPEED LIMIT This constant is the RPM at which an alarm is desired if the sensed fan speeds up. 32
Developing Constants Liquid System LESSON 5 The console requires constants (fi xed numbers) to accurately compute displayed information and to control the application rate of the product. It is very important to understand what constants are required and how to arrive at the correct numbers (constants) for programming (entering into memory) the console. In this lesson, you will learn how to: Defi ne a constant for both the CCS100 and the CMS100 console units. Determine accurate values to enter into memory. Constants are entered into the Setup Mode Memory locations of the CCS100 to describe the sprayer vehicle capabilities to the control console. The console uses these values (numbers) to accurately compute the application rate of the product. It is therefore very important that you understand what constants are required and how to arrive at the correct numbers (constants) for programming (entering into memory) the console. When entering numbers, the decimal point can always be positioned as desired. All constants must be entered before the system will function, including the ground speed calibration. Determining CCS100 Constants A. P, Pn or F Select P for sprayer (pressure based system), Pn for sprayer with nozzle monitor. B. APPLICATION RATE This value is the volume of product to be applied per unit of area; gallons per acre (liters per hectare). The value must be within the delivery capabilities of the sprayer system. The decimal point may be positioned as required. Depress and hold the center touchswitch and note that the decimal begins to sequence from right to left. The value of the constant depends on the placement of the decimal point. Example: An application rate of 20 gallons per acre can be entered as: 20.00 or 020.0 or 0020 C. APPLICATION RATE +/- (change-on-the-go) This value is the desired increment of change in gallons per acre (liters per hectare) and allows the operator the option of increasing or decreasing the application rate by a specifi ed increment, while moving through the fi eld. D. NOZZLE SPACING The nozzle spacing is the distance in inches (meters) between nozzles on the spray bar for broadcast operations. The value to enter is determined by measuring the distance between nozzles to nearest 1/10 inch. Example: 25 inch nozzle spacing can be entered as: 25.00 or 025.0 or 0025 E. NOZZLE (Capacity) PRESSURE This constant is the reference liquid pressure in psi at which the nozzle fl ow (capacity) constant is obtained. F. NOZZLE FLOW (Capacity) The fl ow of one nozzle in gallons per minute at the corresponding nozzle reference pressure. The Nozzle Pressure and Nozzle Flow constants are obtained from your Nozzle Manufacturer s Specifi cation Sheet. Refer to the section of the specifi - cation sheet containing the nozzle data for the nozzles that you have selected to use. The nozzle data will normally list several pressures with the corresponding nozzle fl ow. Select the pressure and nozzle fl ow that are closest to 33
the pressure you anticipate the spray bar to have when operating. Enter these values for the nozzle pressure and nozzle fl ow constants. GALLONS PER ACRE Capacity Capacity 1 Liquid 1 Nozzle 20 NOZZLE SPACING 30 NOZZLE SPACING NOZ- Pressure in in Nozzle in 7 7 8 ZLE NO. PSI GPM oz./min. 5 MPH6 MPH MPH 8 MPH 5 MPH 6 MPH MPH MPH 30 12 15 6.9 5.7 4.9 4.3 4.6 3.8 3.3 2.9 40 13 17 8.0 6.6 5.7 5.0 5.3 4.4 3.6 3.3 50 15 19 8.9 7.4 6.4 5.6 5.9 4.9 4.2 3.7 60 16 20 9.7 8.1 7.0 6.1 6.5 5.4 4.6 4.1 30 17 22 10.3 8.6 7.3 6.4 6.9 5.7 4.9 4.3 40 20 26 11.9 9.9 8.5 7.4 7.9 6.6 5.7 4.9 50 22 28 13.3 11.1 9.5 8.3 8.9 7.4 6.3 5.5 60 24 31 14.6 12.1 10.4 9.1 9.7 8.1 6.9 6.1 30 26 33 15.4 12.9 11.0 9.6 10.3 8.5 7.3 6.4 40 30 38 17.8 14.9 12.7 11.1 11.9 9.9 8.5 7.4 50 34 44 19.9 16.6 14.2 12.5 13.3 11.1 9.5 8.3 60 37 47 22 18.2 5.6 13.6 14.6 12.1 10.4 9.1 30 35 45 21 17.1 14.7 12.9 13.7 11.4 9.8 8.6 40 40 51 24 19.8 17.0 14.8 15.8 13.2 11.3 9.9 50 45 58 27 22 19.0 16.6 17.7 14.8 12.7 11.1 60 49 63 29 24 21 18.2 19.4 16.2 13.9 12.1 30 52 57 31 26 22 19.3 21 17.1 14.7 12.9 40 60 77 36 30 25 22 24 19.8 17.0 14.8 50 67 86 40 33 28 25 27 22 19.0 16.6 60 73 93 44 36 31 27 29 24 21 18.2 30 69 88 41 34 29 26 27 23 19.6 17.1 40 80 102 48 40 34 30 32 26 23 19.8 50 89 114 53 44 38 33 35 30 25 22 60 98 125 58 49 42 36 39 32 28 24 Example: Your sprayer has 20 nozzle spacing. Desired GPA = 30 GPA Desired Ground Speed = 6 MPH Referring to the above typical nozzle specifi cation sheet, fi nd the data for the example nozzle. Note that for the 20 nozzle spacing, 30 GPA and 6 MPH a 40 psi spray bar operating pressure will be expected. The constants for this example are: E. NOZZLE (CAPACITY) PRESSURE CONSTANT = 40 psi F. NOZZLE FLOW (CAPACITY) CONSTANT =.60 gpm G. FLUSH PRESSURE This constant is set to the desired pressure in psi (bars) that the system will obtain, at the spray bar, when the OFF/AUTO/ FLUSH switch is held in the FLUSH position. This constant is very useful when performing catch tests to check nozzle accuracy. 34
Conversion Factor Weight of Solution Lbs. (per U.S. Gal.) Liquid Solutions with 1-2.5% Clay 7.92 7.5.95 8.98 8.34 (water) 1.0 8.5 1.01 9 1.04 1.16 9.5 1.08 1.2 10 1.1 1.22 10.5 1.12 1.24 11 1.15 1.27 11.5 1.18 1.29 12 1.2 1.32 12.5 1.22 1.34 13 1.25 1.37 13.5 1.27 1.4 14 1.3 1.43 14.5 1.32 1.44 15 1.34 1.46 15.5 1.36 1.48 16 1.39 1.5 16.5 1.41 1.53 17 1.43 1.55 17.5 1.45 1.57 18 1.47 1.59 H. CONVERSION FACTOR The conversion factor compensates for the density of the product being sprayed. It compares the weight of 1 gallon (liter) of product to 1 gallon (liter) of water. Conversion Factor - weight of 1 gallon (liter) of product 8.333 lbs (1 kg) Determine the exact weight per gallon (liter) of product being sprayed, to the nearest tenth pound (kg). Make certain the sample used is well mixed and truly represents your product. The more care taken in measuring and weighing, the more accurate the application rate. Use the above formula or refer to the following tables to determine the conversion factor. If suspension fertilizers are being applied, the recommended conversion factor may be not correct (serves as a guide only) as product viscosity and consequently nozzle fl ow rate is affected by the fertilizer blending process. The CONVERSION FAC- TOR must be adjusted accordingly. I. ZERO PRESSURE CALibration This number matches the pressure transducer to the control console. This number is obtained by performing the following procedure: Important: There must be zero pressure on the spray bar at the location of the pressure transducer when performing this calibration. Check valves or no drip nozzles may retain pressure on the boom. Depress and hold the right (0-9) touchswitch for approximately 5 seconds or until the full display stops fl ashing and the continuous alarm stops sounding. After the alarm stops, the Calibration is complete and the number shown on the display is the Zero Pressure Calibration value. J. SYSTEM RESPONSE This constant is a number that affects the response time as well as the steady operation error state of the control valve to correct for an application error that is created by a change in ground speed. When this number is set correctly the control system responds to a change in ground speed by repositioning the control valve with a slight overshoot and without causing oscillation around the new product fl ow rate. The System Response Constant is factory set to 3.0 as a beginning point. During fi eld operation, if one of the following symptoms is observed this value should be changed in the direction described. 1. If the console display fl uctuates above and below the targeted application rate by a large amount (10% to 20%), this indicates that the SYSTEM RESPONSE Constant is too large and should be decreased in value (see Note below). 2. If the console display is slow in responding to a change in ground speed or application rate (change-on-the-go) or it stabilized at some indication other than the targeted application rate, this indicates that the SYSTEM RESPONSE Constant is too small and should be increased in value. 35