Introduction... 5 System Description... 5 Preparing for Installation... 6 Installing The CCS100 NH3 Control System... 7

Transcription

1 TABLE OF CONTENTS Safety Notices... 3 Introduction... 5 System Description... 5 Preparing for Installation... 6 Installing The CCS100 NH3 Control System... 7 Setup... 9 Initial Power Up Of System Operate Mode Setup Mode Constants P, Pn, or F Application Rate Application Rate +/- (Change On The Go) Implement Width Density Flow Sensor Constant Flush Flow Rate Bargraph Maximum Flow Rate ( 10) System Response Ground Speed Calibration Preparing For Operation Control Valve Stationary Check Verifying Accuracy Application Rate Fine Tuning Operation Field Operation (All Constants Entered) Incremental Application Rate (Change On The Go) Bargraph Flush Mode Display Messages OFF APER (Application Rate Error) Bargraph Digit Display Flashing 4-Digit Display Checkmark Flush Mode Manual Override Troubleshooting Applicators Anhydrous Ammonia Control System Control Console Will Not Turn On APER Message Displayed, Alarm Sounds Control Valve Will Not Open In AUTO Mode While Moving Through The Field Fuse Blows When Replaced Temporary Field Repair (Cables) Service Notes i

2 TABLE OF CONTENTS Appendix A Handling Anhydrous Ammonia Physiological Responses to Ammonia Vapor Characteristics of Anhydrous Ammonia Appendix B System Capacity Considerations Continental Super Flow Thermal Transfer Unit NH3 System Flow Rates Operating Principles Recommendations Appendix C Handling Trapped Anhydrous Ammonia Warranty ii

3 REFER TO MATERIAL SAFETY DATA SHEETS (MSDS) AND OTHER PERTINENT SAFETY REQUIREMENTS ASSOCIATED WITH THE HANDLING AND APPLICATION OF ANHYDROUS AMMONIA (NH 3 ) WITH A LOCAL ANHYDROUS AMMONIA SUPPLIER. It is recommended that users also consult other helpful sources concerning proper procedures for handling anhydrous ammonia and related equipment use, e.g., The National Ag Safety Database ( and the Fertilizer Institute, th Street, NW, Washington, DC VALVES AND OTHER COMPONENT PARTS DO FAIL FROM TIME TO TIME ACCORDING TO THEIR USEFUL LIFE. INSPECT AND REPLACE COMPONENT PARTS PURSUANT TO MANUFACTURER S GUIDELINES. IF COMPONENT S USEFUL LIFE IS NOT INCLUDED IN A MANUFACTURER S GUIDELINES, CONSULT WITH THE COMPONENT MANUFACTURER. 1

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5 SAFETY NOTICES Safety notices are one of the primary ways to call attention to potential hazards. This Safety Alert Symbol identifies important safety messages in this manual. When you see this symbol, carefully read the message that follows. Be alert to the possibility of personal injury or death. Use of the word WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Use of the word CAUTION with the Safety Alert Symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Use of the word CAUTION without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in equipment damage. SAFETY NOTICES 3

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7 INTRODUCTION SYSTEM DESCRIPTION The CCS100 Custom Control System offers a compact unit that provides maximum control over the gallons or pounds per acre of liquid, granular, or anhydrous material applied, even with ground speed changes. The application rates are adjustable, even in the field, due to a simple three-button control panel and a high-speed valve that opens and closes in less than 2 seconds. The CCS100 offers: dual digital readout of pressure and gallons per acre dual digital readout of pounds per hour and pounds per acre compact size that maximizes cab space plugged nozzle indicator English or metric versions available information preserved even with power loss The Spreader Control System consists of (each sold individually): CCS100 console Switch Module Hydraulic Control Valve Flow Meter Thermal Transfer Unit Ground Speed Sensor When installed on your anhydrous ammonia applicator, the flow of product varies automatically in proportion to the changes in ground speed keeping the application rate uniform throughout the field. Figure 1 CCS100 INTRODUCTION 5

8 Refer to the following harnessing diagram that illustrates the connection relationship of the control system components. The connectors on each of the system components are selected so that the component connector only mates to the correct harness cable connector. Figure 2 Harnessing Diagram djccs100 CONSOLE SWITCH MODULE MAIN HARNESS RADAR II GROUND SPEED SENSOR * 12V BATTERY FUSE OPTIONAL LIFT SWITCH IMPLEMENT HARNESS CONTROL VALVE NOT USED FLOWMETER OPTIONAL VAPOR DETECTOR PREPARING FOR INSTALLATION 1. Unpack and visually inspect the system components for damage that may have occurred during shipping. If damage is found, file a claim immediately with the carrier and notify your DICKEY-john dealer. 2. Check against the purchase invoice to ensure all monitoring components were received. IMPORTANT: Refer to APPENDIX C for a method of draining the applicator. 3. Check the applicator thoroughly. 4. Inspect hoses and check for breaks or softening in the cover, blistering, swelling, loose couplings, or damage to the hose reinforcement. These 6 INTRODUCTION

9 Figure 3 Anhydrous Ammonia Plumbing Schematic (Single Manifold System) defects should be corrected or the hose should be replaced. Replace hoses as recommended by the manufacturer. 5. Make certain the safety break-away coupling is free to operate properly. Clean and service the coupling in accordance with manufacturer s instructions. INSTALLING THE CCS100 NH 3 CONTROL SYSTEM Refer to the following illustrations for typical placement of the control system components in the anhydrous ammonia applicator system. NURSE TANK SHUTOFF QUICK DISCONNECT COUPLING ANHYDROUS AMMONIA SHUTOFF VALVE BLEEDER PRESSURE RELIEF *ELECTRIC, MANUAL, OR HYDRAULIC THERMAL SHUTOFF VALVE TRANSFER UNIT CONTROL VALVE FLOW METER MANIFOLD NURSE TANK BLEEDER SAFETY BREAK-AWAY CONNECTOR AMMONIA TRANSFER HOSE (1" or 1-1/4" - 350psi) SWITCH MODULE LIFT SWITCH (optional) GROUND SPEED SENSOR CONTROL CONSOLE AMMONIA TRANSFER HOSE (1" - 350psi) IMPLEMENT KNIVES (8) *This Valve(s) is necessary to provide shutdown capability in the event of electrical failure.this Valve(s) may be part of the existing regulator. During operation, regulator should be adjusted to full open position. INTRODUCTION 7

10 Figure 4 Anhydrous Ammonia Plumbing Schematic (Dual Manifold System) for Dj Thermal Transfer or Super Flow SUPERFLOW IMPLEMENT KNIVES (8) CONTROL VALVE FLOWMETER *ELECTRIC, MANUAL, OR HYDRAULIC SHUTOFF VALVE MANIFOLD PRESSURE RELIEF NURSE TANK SHUTOFF QUICK DISCONNECT COUPLING NURSE TANK ANHYDROUS AMMONIA SHUTOFF VALVE BLEEDER BLEEDER SAFETY BREAK-AWAY CONNECTOR PRESSURE RELIEF THERMAL TRANSFER UNIT CONTROL VALVE FLOW METER IMPLEMENT KNIVES (8) AMMONIA TRANSFER HOSE (1" or 1-1/4" - 350psi) CONTROL CONSOLE AMMONIA TRANSFER HOSE (1" - 350psi) MANIFOLD SWITCH MODULE LIFT SWITCH (optional) *ELECTRIC, MANUAL, OR HYDRAULIC SHUTOFF VALVE GROUND SPEED SENSOR *This Valve(s) is necessary to provide shutdown capability in the event of electrical failure.this Valve(s) may be part of the existing regulator. During operation, regulator should be adjusted to full open position. Refer to the Installation Instructions supplied with each control system component for detailed installation procedures. Refer to Appendix for additional anhydrous ammonia instructions. VALVES AND OTHER COMPONENT PARTS DO FAIL FROM TIME TO TIME ACCORDING TO THEIR USEFUL LIFE. INSPECT AND REPLACE COMPONENT PARTS PURSUANT TO MANUFACTURER S GUIDELINES. IF COMPONENT S USEFUL LIFE IS NOT INCLUDED IN A MANUFACTURER S GUIDELINES, CONSULT WITH THE COMPONENT MANUFACTURER. 8 INTRODUCTION

11 SETUP After the control system has been installed on the applicator, it can be powered up. Do not charge the system with anhydrous ammonia. This procedure is only used for familiarization to control console operation. Figure 5 Operator Controls SETUP POSITION IDENTIFIER DISPLAYED IN SETUP MODE BARGRAPH A B C D E F G H I J SETUP USED WITH VAPOR DETECTOR 4-DIGIT DISPLAY APER ON OFF POWER SWITCH APPLICATION RATE OPER 9 SETUP 0 APPLICATION RATE ERROR DICKEY-john R DjCCS100 OPERATE MODE - RETURN TO TARGET APPLICATION RATE - LOCK SYSTEM IN FLUSH MODE - HOLD FOR 3 SECONDS TO ENTER SETUP MODE SETUP MODE - SELECT CONSTANT LOCATION - HOLD FOR 3 SECONDS TO ENTER OPERATE MODE OPERATE MODE - DECREASES APPLICATION RATE SETUP MODE - SELECTS DIGIT - POSITIONS DECIMAL POINT - STARTS AND STOPS GROUND SPEED CALIBRATION OPERATE MODE - INCREASES APPLICATION RATE SETUP MODE - SETS DIGITVALUE Figure 6 Switch Module A U T O FLUSH OFF A U T O OFF - Provides a control valve shutoff command to the control console. AUTO - Provides the control console with a command that initiates automatic control system operation. Application rate is controlled with ground speed as reference. FLUSH - Provides the control console with a command that causes the control valve to open to a pre-programmed flowrate. Remains as long as the switch is held in FLUSH. *No functions in SETUP mode. SETUP 9

12 INITIAL POWER UP OF SYSTEM The CCS100 Control System has two active modes: OPERATE mode used during normal field operation SETUP mode used to enter constants that describe the anhydrous ammonia applicator to the control console. NOTE: 9 0 When power is turned ON, the control system will always power up in OPERATE mode. Increment switch Decrement switch OPER SETUP Operate switch OPERATE MODE 1. Place the Power Switch in the ON position. When the Power Switch is set to ON, the console will sound an alarm and display all segments for one second. 2. For the next second, the programmed value for application rate (APR) will display. 3. The console will enter OPERATE mode and display the current APR, which will be zero (0). 4. If the display shows OFF, toggle the OFF/AUTO/FLUSH switch to the OFF position. In OPERATE mode, the display will show pounds per acre. The Increment and Decrement switches are used to increase or decrease the APR by a programmed increment. Any time the APR has been incremented from the targeted APR, the displayed pounds per acre will flash. 5. Press the Increment or Decrement switches. The displayed zero will begin to flash. 6. To return to the targeted APR, press the Operate switch. The zero will cease flashing. Each valid touch switch closure is accompanied by a short burst from the alarm. SETUP MODE Refer to the CONSTANTS DECAL provided with the control system. The CONSTANTS DECAL is used for explanation purposes. It may or may not be identical to the decal sent with your system (Figure 7). IMPORTANT: The decal supplied must be used with their individual system when entering constants in order to match the SETUP POS (pointer location) to the constant s description. 10 SETUP

13 Figure 7 Constants Decal SPRAYER SETUP CONSTANTS POS. A P or Pn B APPLICATION RATE C APPLICATION RATE +/- D NOZZLE SPACING E NOZZLE CAPACITY PRESSURE F NOZZLE FLOW CAPACITY G FLUSH PRESSURE H CONVERSION FACTOR I ZERO PRESSURE CALIBRATION J SYSTEM RESPONSE A NOZZLE MONITOR SET B GROUND SPEED CALIBRATION C PRESSURE LIMITS SET ANHYDROUS AMMONIA SETUP CONSTANTS POS. A F B APPLICATION RATE C APPLICATION RATE +/- D IMPLEMENT WIDTH E DENSITY F FLOW SENSOR CONSTANT G FLUSH FLOW RATE ( 10) H BARGRAPH MAX. FLOW RATE ( 10) I SYSTEM RESPONSE J GROUND SPEED CALIBRATION Note that SETUP POS. A in the SPRAYER CONSTANT column shows P or Pn and the ANHYDROUS AMMONIA CONSTANT column shows F. When P or Pn is selected, the SETUP POS. and CONSTANTS to be entered are shown in the Sprayer Column. When F is selected, the SETUP POS. and CONSTANTS to be entered are shown in the Anhydrous Ammonia column. 7. Enter the SETUP mode by pressing and holding the Operate switch for approximately 3 seconds. The SETUP mode is identified by the word SETUP flashing in the upper right hand corner of the display, along with a single bargraph segment (pointer) displayed under the A of the setup scale. Figure 8 Setup Mode A B C D E F G H I J SETUP ON OFF OPER APPLICATION RATE 9 SETUP 0 DICKEY-john R DjCCS With the setup pointer under the A, the console will display either P, Pn, or F. Press the Increment switch and note that the display increments through those three letters as the switch is pressed. 9. Using the Increment switch, set the display to F. SETUP 11

14 10. Press the Operate switch and the cursor increments to SETUP POS. B. The display will show 4 digits with the left most digit flashing. Figure 9 Setup Mode - 4 Digits A B C D E F G H I J SETUP ON OFF OPER APPLICATION RATE 9 SETUP 0 DICKEY-john R DjCCS Press the Decrement switch. The digit to the right of the left most digit will begin to flash. Repeatedly pressing the Decrement switch will toggle the flashing digits from left to right across the display. The flashing digit indicates the digit to change when the Increment switch is pressed. 12. Press the Increment switch and the flashing digit will increase by one count. Repeatedly selecting the Increment switch will sequence the digit from 0 (zero) through 9 (nine). The value of the digit is displayed. 13. Press and hold the Decrement switch and the decimal point will begin to sequence from right to left. When the decimal point is not shown on the display, the 4 digits comprise a whole number. The value of the constant depends on the placement of the decimal point. NOTE: To become familiar with the constant locations, repeatedly select the Operate switch while referring to the CONSTANT DECAL. The cursor will increment to each SETUP number shown on the decal. SETTING INDIVIDUAL DIGITS AND DECIMAL TO DISPLAY THE DESIRED VALUE OF THE 4-DIGIT CONSTANT When GROUND SPEED CALIBRATION is first entered (on the display), the right 4 digits display the constant s current value with the most significant digit flashing. This location is used to enter a known constant or an average of several calibration procedures. 1. Press the Operate switch. All 4 digits will begin to flash. This location is used when performing GROUND SPEED CALIBRATION. 2. When reaching the last constant location as provided on the CONSTANT DECAL, selecting the Operate switch again will result in the first constant location to display. Each constant location displays in sequence again and again by selecting the Operate switch. 3. This cycle will continue until the SETUP mode is exited by pressing and holding the Operate switch for approximately 3 seconds. 12 SETUP

15 CONSTANTS OPER SETUP Operate switch The constants to be entered onto SETUP mode memory locations describe the Anhydrous Ammonia applicator to the Control Console. The console uses the entered values to make computations necessary to accurately control the application rate (APR). Enter SETUP mode by pressing and holding the Operate switch for approximately 3 seconds. P, PN, OR F Select F for anhydrous ammonia application. APPLICATION RATE The Application Rate is the volume of product to be applied per unit of area, displayed in pounds per acre (kilograms per hectare). The value can be entered as NH 3 per acre or N (Nitrogen) per acre. The decimal point can be positioned as required. APPLICATION RATE +/- (CHANGE ON THE GO) The Application Rate +/- provides the option of increasing or decreasing the application rate by a specified amount while moving through the field. Placement of the decimal point is fixed by placement in APPLICATION RATE as stated above. IMPLEMENT WIDTH The Implement Width Constant is the width of the applicator measured in feet (meters). The decimal point can be positioned as required. DENSITY The Density Constant is the product weight in pounds (kilograms) per cubic foot (liter) of NH 3 or the weight in pounds (kilograms) of nitrogen contained in one cubic foot (liter) of NH 3. The decimal point can be positioned as required. IMPORTANT: If the Application Rate Constant is selected to be in pounds of NH 3 per acre, the density must be in pounds per cubic foot NH 3. If the Application Rate Constant is selected to be in pounds of Nitrogen per acre, the density must be in pounds per cubic foot of Nitrogen. CONSTANTS 13

16 Refer to the following table to obtain the density of NH3 or Nitrogen at the operating pressure of the nurse tank. NURSE TANK NURSE TANK POUNDS PER CUBIC POUNDS PER CUBIC O TEMPERATURE F PRESSURE (PSI) FOOT NH3 FOOT NITROGEN Read the nurse tank pressure gauge and round down to the nearest pressure listed in the Density Table. For example, if the nurse tank pressure gauge read 49 psi, then use the 40 psi listing on the table. If the tank pressure gauge is inoperative, the tank temperature can be used to determine the approximate density values. 2. Obtain the density from the table using the appropriate column. The decimal point can be positioned as required. FLOW SENSOR CONSTANT The flow sensor constant is a calibration number. This number is written on the side of the flow meter. The decimal point can be positioned as required. Record the flow sensor constant for future reference: FLUSH FLOW RATE The flush flow rate constant in pounds (kilograms) per hour is the flow rate the system will attain when the OFF/AUTO/FLUSH switch is held in the FLUSH position. Divide the desired value by 10 to enter. For example: 4000 lbs/hr is entered as 400. The decimal point can be positioned as required. BARGRAPH MAXIMUM FLOW RATE ( 10) The bargraph maximum flow rate constant sets the full scale value of the bargraph display. The units are pounds (kilograms) per hour divided by 10. The value to enter is recommended as follows: 3/4 Valve - 1TTU Valve - 1TTU Valve - 2TTU /4 Valve - Super Flow System CONSTANTS

17 NOTE: Change the System Response Constant value by 1 count in the indicated direction. Repeat the procedure until the control system operates satisfactorily. For fine tuning, values in.1 (tenth) units may be entered. For example, 2.5 rather than 2 or 3. To calculate the flow rate: Fr= (APR)(MPH)(W) (.1212) Where: Fr = Flow rate in lbs/hr APR = Application Rate in lbs/acre MPH = Miles per hour W = Width of applicator in feet The decimal point can be positioned as required. SYSTEM RESPONSE The System Response Constant is a number that affects the control valve response time as well as the steady operation accuracy. When this number is set correctly, the control system will respond to a change in ground speed by repositioning the control valve with a slight overshoot and without causing oscillation around the new product flowrate. The System Response Constant is factory set to 3.0 as a beginning point. During field operation, if one of the following symptoms is observed, the value should be changed in the direction indicated. If the console display fluctuates above or 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. 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, the System Response Constant is too small and should be increased in value. The decimal point can be positioned as required. GROUND SPEED CALIBRATION The Ground Speed Calibration Constant is a number that matches the Ground Speed Sensor to the Control Console. To obtain this constant, the vehicle is driven over a measured course while performing the following procedure. OPER SETUP Operate switch 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 first entered when the pointer increments to SETUP POS J and is identified by a single digit flashing. This entry method is used to enter an average that is obtained by performing the calibration procedure several times. Averaging of the calibration procedure numbers will enhance the accuracy of the vehicle ground speed. Touching the Setup switch advances to the second method, which is identified by all four digits flashing on the display. 1. Measure a 400 foot (122 meter) infield course (preferably on level ground). CONSTANTS 15

18 Decrement switch 2. Mark the start and finish points so they are clearly visible from the tractor cab. 3. The system must be in SETUP mode with the pointer in the second Ground Speed Calibration position (all digits flashing). 4. Drive to the start marker at a minimum of 2 mph (4 km/h) operating speed. 5. When the tractor is even with the start marker, press the Decrement switch. The display readout should reset to 0 (zero) and start counting as the tractor travels forward. 6. Continue to drive the measured course at a constant speed. When even with the finish marker, select the Decrement switch again. 7. The Ground Speed Calibration number will display on the console s readout. 8. Record the number for future reference. Ground Speed Calibration Number: IMPORTANT: It is recommended that this procedure be repeated 3 or 4 times and averaged. Enter the resulting average in console memory using the manual entry method. 16 CONSTANTS

19 PREPARING FOR OPERATION CONTROL VALVE STATIONARY CHECK IMPORTANT: This procedure is performed without a nurse tank. 1. Turn the console power switch to the ON position. Make sure the OFF/ AUTO/FLUSH switch is set to OFF. 2. Press and hold the OFF/AUTO/FLUSH switch to the FLUSH position. If possible, watch the control valve coupling to verify that it rotates to the full open position. When the control valve reaches full open, the console APER message will flash and the alarm will sound. 3. Return the OFF/AUTO/FLUSH switch to the OFF position. The valve coupling should rotate back to the closed position. 4. Verify the control valve is closed, (Figure 10). 5. If the control valve does not respond, recheck installation procedures and correct the problem. Figure 10 Valve Assembly (Without Motor Actuator Assembly) COUPLING CLOSED POSITION CONTROL VALVE VERIFYING ACCURACY Accuracy of the control system can be affected by many factors. Accuracy should be checked after first installing the system and after starting the system for the first time each season. To check accuracy: 1. Select a field where the area is known to be accurate (preferably 10 acres or more). 2. Weigh the nurse tank and record the number. 3. Apply product to the field as in normal operation. 4. When finished, weight the nurse tank and record the number. PREPARING FOR OPERATION 17

20 5. To determine the amount of product applied per acre: Tank weight at start (minus) tank weight at finish acres covered = pounds of NH applied per acre 3 Pounds of NH3 applied per acre x.82 = pounds of actual Nitrogen per acre 6. To determine percent error: Actual lbs per acre (minus) desired lbs per acre desired lbs per acre x 100 = % error For example: Tank weight at start 4200 pounds Tank weight at finish 1900 pounds Acres covered 10 Desired pounds per acre 200 actual nitrogen = 230 pounds of NH 3 per acre 230 lbs of NH3 applied per acre x.82 = lbs of actual nitrogen per acre If you experience an application rate error of greater than +/- 10%, examine the following calibration constants. Ground Speed Calibration Was the ground speed calibration run on an accurate 400 foot course (not 390 or 415 feet, or 133 1/3 paces). Has the radar angled changed since the ground speed calibration was performed. Density Is the density set correctly for the appropriate tank pressure or temperature. If the application rate for pounds of nitrogen was set, is the density set for pounds per cubic foot nitrogen or pounds per cubic foot anhydrous ammonia. The appropriate column must be used from the Density Table or an +/- 18% error will be experienced. Flow Meter = x 100 = -5.7% error Ensure flow meter is installed correctly. There is an in and out orientation to the flow meter that must be correct. Is the correct flow meter constant entered and the decimal point positioned correctly. APPLICATION RATE FINE TUNING If, over a period of time, a small (less than 10%) application rate error is consistently under or over the target, the control system can be fine tuned. These small errors can be the result of anhydrous ammonia applicator variations. 18 PREPARING FOR OPERATION

21 1. Determine the new flow meter constant as follows: New Flowmeter Constant = (Old Spreader Constant) Desired APR Actual APR For example, if the application rate was programmed for 200 lbs per acre and over a period of time the actual application was determined to be 208 lbs per acre, an adjustment could be made to the Flow Meter Constant value using the formula illustrated above. Desired APR = 200 Actual APR = 208 Old Flow Meter Constant = 2.15 (2.15) 200 = 2.15 x.9615 = or New Flow Meter Constant is 2.07 (enter the new constant using the SETUP mode. Raise the Flow Meter Constant to RAISE the amount of material applied. Lower the Flow Meter Constant to LOWER the amount of material applied. PREPARING FOR OPERATION 19

22 20 PREPARING FOR OPERATION

23 OPERATION The System in the normal operating mode will display the pounds (kilograms) per acre (hectare) of Anhydrous Ammonia or Nitrogen applied. Figure 11 Control Console And Switch Module FIELD OPERATION (ALL CONSTANTS ENTERED) 1. Set the OFF/AUTO/FLUSH switch to OFF. 2. Power the console ON/OFF switch to ON. 3. Ensure the control valve is in the CLOSED position. At the beginning of the season, the control valve operation should be completely checked. If the control valve does not respond as described in CONTROL VALVE STATIONARY CHECK, the system must not be charged with Anhydrous Ammonia. 4. Charge the system with NH 3. Starting at the nurse tank, slowly open the shutoff valves and check for leaks. This charges the system up to the control valve. IMPORTANT: If a leak is detected, the system must be shut down and drained of all NH 3. Fix the leak and recharge. Do not weld on any system parts that might contain residual NH 3 liquid or vapor. OPERATION 21

24 5. To begin applying NH 3, put the applicator in the ground and hold the OFF/AUTO/FLUSH switch in the FLUSH position for approximately 10 seconds. This will allow the system downstream from the control valve to fill with NH 3 and the Thermal Transfer Unit to begin functioning (cooling the NH 3 ). 6. Release the OFF/AUTO/FLUSH switch from the FLUSH position (automatically returns to AUTO). The control system will now control to the programmed application rate. It is recommended that the application rate is calculated by dividing the number of acres covered by the pounds of NH 3 applied (obtained from the nurse tank ticket) to ensure the product is not grossly under applied. If it is suspected that under application is occurring, slow the applicator ground speed. INCREMENTAL APPLICATION RATE (CHANGE ON THE GO) 9 0 Increment switch Decrement switch OPER SETUP Operate switch When in OPERATE mode, the Application Rate can be adjusted while moving through the field by pressing the Increment or Decrement switches to increase and decrease the application rate, respectively. Each time a switch is pressed, the controlled application rate will be increased or decreased by the amount entered in the + and - Application Rate (Change On The Go) Constant location. The altered application rate is indicated by the displayed value flashing on and off. To return to the programmed Application Rate, press the Operate switch (the display will not flash). BARGRAPH The bargraph, located at the top of the display console, indicates product flow in pounds (kilograms) per hour. If the maximum flow rate is set to 6,000 pounds per hour and the bargraph indicates half scale, it would represent 50% of 6,000, or 3,000 pounds per hour. With the maximum flow rate set at 6,000 pounds per hour, each bar would represent 200 pounds per hour (6,000 lbs/hr divided by 30 equals 200 lbs/hr). The bargraph provides a good indication of system stability. For a tractor with a ground speed variation of +/-.5 mph, the bargraph should be fairly steady. Bars should flash one or two bars on each side of the average during application. If the bargraph is changing wildly (ground speed is steady), the System Response Constant is too large. Refer to CONSTANTS for additional information. FLUSH MODE The FLUSH mode provides the console with a command that causes the control valve to open to a programmed flow rate (Flush Flow Rate Constant). The command will remain as long as the OFF/AUTO/FLUSH switch is in the FLUSH position, or the console can be locked in the FLUSH position by pressing the Operate switch while in FLUSH mode. Locked FLUSH can be removed by setting the OFF/AUTO/FLUSH switch to OFF. 22 OPERATION

25 DISPLAY MESSAGES OPER SETUP Operate switch OFF When the OFF message displays, the OFF/AUTO/FLUSH switch must be returned to the OFF position before attempting to apply product. This message will display if the OFF/AUTO/FLUSH switch is in the AUTO position when power is turned ON, SETUP mode is exited, or there has been no ground speed signal for approximately one minute. APER (APPLICATION RATE ERROR) This message displays when the control valve is at its maximum open position. It flashes on and off and is accompanied by a burst from the audible alarm. This message can be caused by downstream flow restrictions such as plugged screens or kinked hoses. BARGRAPH Indicates current pounds per hour (Kg/hr) being applied. 4-DIGIT DISPLAY Indicates actual application rate in pounds per acre (Kg/hectare). FLASHING 4-DIGIT DISPLAY +/- application rate has been activated. CHECKMARK Displays when the Vapor Detector (optional) detects a threshold level of vapor in the flow of liquid NH 3. The alarm will sound for approximately 3 seconds. FLUSH MODE MANUAL OVERRIDE All constants must be entered in the CCS100 Console as described in the CONSTANTS section of this manual. The Flush Flow Rate Constant can be calculated and entered as follows, or obtained from Tables 1-3. Flush Flow Rate = (APR)(MPH)(W)(.1212) 10 Where: APR = Application Rate in lbs per acre MPH = Vehicle Ground Speed in miles per hour W = Implement width in feet OPERATION 23

26 Example: If application of 150 lbs per acre at 5 mph with an implement width of 20 feet is desired, the calculation is as follows: FFR= (150)(5)(20)(.1212) 10 = Enter as the Flush Flow Constant. In the Flush Mode Manual Override, the amount of material applied will not be controlled proportional to ground speed. The ground speed used in the formula illustrated above must be maintained to provide the desired application rate. 24 OPERATION

27 TROUBLESHOOTING Before performing troubleshooting, the applicator must be drained of all Anhydrous Ammonia. Refer to APPENDIX C for draining procedures. APPLICATORS Symptom Probable Cause Corrective Action APER message displayed, alarm sounds when attempting to apply Anhydrous Ammonia. Suspected inaccurate Application Rate Regulator screen plugged. Downstream Manual, Hydraulic, or electrical valves are closed. Improper Application Rate Constant entered - not updated. Incorrect field driving interval. Field area larger or smaller than used in determining amount of product to use. Above capacity of system. Clean screens. Open valves. Check all constants for proper values. Measure and correct. Recheck calculations. Reduce Ground Speed (refer to APPENDIX B) for system capacity considerations. ANHYDROUS AMMONIA CONTROL SYSTEM CONTROL CONSOLE WILL NOT TURN ON Probable Cause: 1. Blown fuse. 2. Battery connections. 3. Damaged power cable. 4. Control Console defective. Corrective Action: 1. Check fuse. Fuse is located in positive battery lead. If blown, replace with a type AGC, 5 amp fuse. 2. Check the battery connections. Make sure there is no corrosion and that they are connected as described in the Installation Instructions. 3. Visually inspect power cable from rear of console to battery. If damage is found, refer to TEMPORARY FIELD REPAIR (CABLE) and make the repairs described. TROUBLESHOOTING 25

28 4. If no problem can be found with the power connection or power cable, the Control Console may be faulty. Contact your distributor or the DICKEY-john Service Department. APER MESSAGE DISPLAYED, ALARM SOUNDS. APER message is displayed (flashing), alarm sounds (indicating that the Control Valve is at its maximum open position). No bars are shown on the bargraph display (indicating that the Application Rate Sensor is not running). Probable Cause: 1. Flow meter cable cut 2. Flow meter paddle wheel jammed. 3. Flow meter Corrective Action: 1. Visually inspect the cabling between the Flow meter and Console. If damage is found, refer to TEMPORARY FIELD REPAIR (CABLE) and make the repairs described. 2. To check the flow meter paddle wheel, the flow meter must be disassembled. Remove the flow meter assembly. Visually inspect the paddle wheel. If it is jammed with debris, it must be cleaned. If the paddle wheel operates freely, the flow meter sensing unit is defective and needs replacement. Before disconnecting any component on the applicator, make absolutely certain that all NH 3 is drained from the hoses, manifold, etc. Wear proper protective gear while working with NH3 system components. Frost on any component is a positive indication of trapped NH 3 at low pressure. Lack of frost does not always indicate a lack of NH Contact your distributor or the DICKEY-john Service Department. CONTROL VALVE WILL NOT OPEN IN AUTO MODE WHILE MOVING THROUGH THE FIELD. Control valve will not open in AUTO mode while moving through the field (bargraph display blank). Control Valve functions normally in FLUSH mode (bargraph display operates in FLUSH mode). Probable Cause: 1. Loss of ground speed input (ground speed sensor or cabling defective). 2. Control Console defective. Corrective Action: This symptom must be isolated to the ground speed sensor cabling, ground speed sensor, or the Control Console. 26 TROUBLESHOOTING

29 1. Visually inspect the cabling between the ground speed sensor and Control Console for pinching, rubbing, and cuts. If damage is found, repair the cable as described in TEMPORARY FIELD REPAIR (CABLES). 2. If no damage is found to the cable, isolate the major components and use the substitution method. Replace one of the suspected components with a known good component. Then test operate the system. If the system performs correctly, the failed component is the one that was replaced. If the system still does not perform correctly and the symptoms remain unchanged, the problem is the component which was not replaced. FUSE BLOWS WHEN REPLACED Probable Cause: 1. Main harness is pinched, cut, or insulation has rubbed off. 2. Switch module, Control Console, ground speed sensor, or optional lift switch defective. 3. Implement harness is pinched, cut, or insulation has rubbed off. 4. Control valve or flow meter is defective. Corrective Action: The troubleshooting of a short circuit in the CCS100 Control System is accomplished by the process of elimination. 1. Since the fuse is located in the power cable and the power cable is part of the main harness, the main harness must be checked first. Disconnect the Control Console, switch module, ground speed sensor, lift switch (if installed), and implement harness from the main harness. Replace fuse. If fuse blows, the main harness is shorted and needs to be repaired or replaced. If the fuse did not blow, set the power switch to OFF and reconnect the Control Console to the main harness. If the fuse blows, it indicates the Control Console is defective and needs to be repaired or replaced. Contact your distributor or the DICKEY-john Service Department. If the fuse did not blow, set the Console power to ON. If the fuse blows when the switch is set to ON, this indicates a short in the Console or main harness. Visually inspect the main harness for pinching, cuts, or insulation rubbed off. If damage is found, repair as described in TEMPORARY FIELD REPAIR (CABLES). If no damage is found, the console may be defective and in need of repair or replacement. Contact your distributor or the DICKEY-john Service Department. 2. Reconnect the switch module, ground speed sensor, and lift switch to the main harness, one at a time. Check the fuse after each connection. If the fuse blows again, suspect the last component or its cable connected to the main harness. Visually inspect the component cable. If damage is found, repair as described in TEMPORARY FIELD REPAIR (CABLES). If no damage is found, the component is defective and needs to be repaired or replaced. 3. Disconnect the control valve and flow meter from the implement harness. Reconnect the implement harness to the main harness. If the TROUBLESHOOTING 27

30 fuse blows, the implement harness is defective and needs to be repaired or replaced. Visually inspect the implement harness for pinching, cuts, or insulation rubbed off. If damage is found, repair as described in TEMPORARY FIELD REPAIR (CABLES). If the fuse does not blow, proceed with Step Reconnect the control valve and flow meter to the implement harness one component at a time. Check the fuse after each connection. If the fuse blows again, suspect the last component or its cable connected to the implement harness. Visually inspect the component cable. If damage is found, repair as described in TEMPORARY FIELD REPAIR (CABLES). If no damage is found, the component is defective and needs to be repaired or replaced. TEMPORARY FIELD REPAIR (CABLES) If any system cable is damaged or cut, it can be repaired in the field. This type of repair is limited to cables only. Do not attempt to repair any wiring inside the hydraulic control valve, the ground speed sensor, or the application rate sensor, as the seals will be broken and the warranty on the system will be void. Do not attempt to repair cable connectors. The following method of repairing cables is only temporary. Units with new cables or new extension cables must be ordered as soon as possible. Otherwise, chemicals may enter the repaired area and damage the components. Always use ROSIN CORE SOLDER for making cable repairs. Never use ACID CORE SOLDER. 1. Carefully cut away the black cable cover at the damaged area. 2. Cut cable packing material. 3. Strip about 1/2 of insulation from damaged lead(s). Do not cut away any of the wire strands. 4. Use alcohol to clean approximately 2 inches of the black cable cover and the individual leads. 5. Twist the two bare leads together (Figure 12) for each damaged lead being careful to match wire colors. 6. Solder the leads using only ROSIN CORE SOLDER. 7. Tape over each repaired lead with vinyl electrical take. 8. Ensure to not use excessive tape. 28 TROUBLESHOOTING

31 Figure 12 Recommended Method - Cable Repairs 9. Add a layer of vinyl electric tape up to the black cable cover at each end of the repaired section. 10. Make a paper trough, as illustrated in Figure 13, and apply silastic compound over the repaired section. Use enough silastic compound to fill in the ends of the black cable. Figure 13 Applying Silastic Compound 11. Allow silastic compound to dry, then use vinyl electrical tape to completely cover the repaired area. 12. Apply tape to at least 2 of each black cable end. 13. Secure repaired cable in such a manner that it will not be damaged again. Figure 14 Applying Vinyl Tape This is only a temporary repair. Replace damaged extension cable or the complete unit if the damaged cable is attached to the unit. Failure to do so will result in damage to the system since active chemicals can creep up through the cable and into one or more of the system units. TROUBLESHOOTING 29

32 30 TROUBLESHOOTING

33 SERVICE NOTES Contact the DICKEY-john Service Department for technical support at Be prepared to answer the following: List all calibration constants entered into the console. Hose size from the tank to the Thermal Transfer Unit. Include the size of the breakaway coupler. Width of the applicator Driving speed Tank pressure Manifold pressure Control valve size What is the console showing for application rate? What is the console showing on the bargraph? For CMS100 monitor, include the Calibration Constants entered What is the speed reading? Is it fluctuating or stable? Is the area functions accumulating correctly? CCS100 Anhydrous Constants A B F Application Rate C Application Rate +/- D E F Implement Width Density Flow Sensor Constant G Flush Flow Rate 10 H Bargraph Max Flow Rate 10 I J System Response Ground Speed Calibration SERVICE NOTES 31

34 32 SERVICE NOTES

35 APPENDIX A HANDLING ANHYDROUS AMMONIA For your own protection, it is important to carefully read, understand, and follow all safety precautions outlined in this manual when handling anhydrous ammonia. Anhydrous ammonia can be very dangerous if improperly handled. All safety procedures must be carefully observed. Serious injury is preventable when safety precautions are observed. It is recommended that protective gloves, boots, slicker and/or pants and jacket, and chemical-splash goggles that are impervious to anhydrous ammonia are worn at all times. These safety precautions are not meant as a substitute for proper training regarding the handling and application of anhydrous ammonia. Do not use or handle anhydrous ammonia without appropriate training. The CCS100 and CMS100 systems are warranted and guaranteed with only DICKEY-john recommended peripheral devices (e.g., radar ground speed sensor, valve actuators, flow meter, etc.) Other manufacturer s devices are not recommended because of unpredictable results, and in some cases can have dangerous consequences. Anhydrous ammonia can cause severe injury if improperly handled. Any person engaged in handling ammonia can reduce risk of serious accidents by observing the following: 1. DO NOT TAMPER WITH SAFETY RELIEF, EXCESS FLOW VALVES, OR OTHER SAFETY DEVICES. 2. DO NOT MODIFY ANY OF THE CONTROL SYSTEM PARTS. 3. A fail safe valve (hydraulic or electric) is required to provide shutdown capability in the event of an electrical failure. 4. Know the product, its characteristics, and behavior. Refer to manufacturer guidelines regarding cleaning, inspecting, maintenance, and replacement of the nurse tank and component parts such as valves and hoses. 5. Use only equipment suitable for anhydrous ammonia service, and make sure it is properly installed - never try to just get by. 6. Make regular inspections of equipment to ensure everything is fully maintained. Always perform corrective measures immediately to maintain a high level of safety. 7. Use and maintain standard protective equipment necessary to safely handle anhydrous ammonia. APPENDIX A 33

36 8. Obtain proper training in handling and applying anhydrous ammonia. 9. Store and handle anhydrous ammonia in accordance with state and local regulations. Where no state or local regulations exist, use only equipment that is constructed in accordance with The Fertilizer Institute Standards. 10. Ensure all ammonia is out of the system before disconnecting or disassembling any parts. Be alert for frosting which is a certain indication of trapped liquid ammonia vaporizing. Depressurize all hoses when not in use. Lack of frost does not always indicate a lack of ammonia. 11. Always repair ammonia leaks immediately. 12. Inspect hoses thoroughly before each season or when the hose has been subjected to abnormal abuse. Ensure hoses are not kinked. Check for breaks or softening in the cover, blistering, swelling, loose couplings or damage to the hose reinforcement. Correct any defects or retire the hose from service. Replace hoses as recommended by the manufacturer. 13. Always pick up a hose by the valve body or coupling, never by the valve handwheel. 14. Always stay clear of valve or hose openings, particularly safety relief valves; even when the system has been depressurized. 15. Use only proper capacity safety relief and excess flow valves - do not tamper with them or other safety devices. 16. Never use wrenches in closing handwheel operated valves. 17. Always stand on the upwind side of ammonia transfer operations. 18. Be certain to wear tight fitting safety goggles or a full-face shield and protective gloves made of rubber or other material impervious to anhydrous ammonia when transferring ammonia. 19. Be certain no person or animal is in line with the discharge before opening any ammonia valve into the air. 20. Close all valves and disconnect all hoses when transfer operations are suspended or unattended. 21. Install an automatic liquid relief (Hydrostatic) valve in any location where a possibility of liquid anhydrous ammonia could be trapped. This valve must open at a safe pressure and discharge into a safe location. 22. Be sure there is a proper shutoff valve on both sides of any point where a disconnect is made. 23. Do not assume that all ammonia is out of the system even when relief valves have been opened and there is zero pressure. Ammonia can remain in the system for several days and sometimes even weeks depending upon weather conditions. 24. Clean, service, and replace safety breakaway valves in accordance with the manufacturer's instructions. 25. Be aware that ammonia can collect in low parts. 26. Do not attempt to modify or lengthen any sensor or flow meter cables. Extension cables are available from your dealer. 27. Running the nurse tank empty or bleeding system through the flow meter may cause damage to the flow meter. 34 APPENDIX A

37 PHYSIOLOGICAL RESPONSES TO AMMONIA VAPOR Concentration of ammonia in the air is measured by parts per million (ppm) and 10,000 ppm = 1%. Exposure levels tolerated by average persons can produce severe respiratory damage to others. First aid for all ammonia victims consists of fresh air and plenty of water for affected areas. The average person s response when exposed to different concentration levels of ammonia vapor are: 5 ppm - Least perceptible odor ppm - Readily detectable odor ppm - No discomfort or impairment of health for prolonged exposure ppm - General discomfort and eye tearing; no lasting effect on short exposure ppm - Severe irritation of eyes, ears, nose, throat; no lasting effect on short exposure. 1,700 ppm - Coughing, bronchial spasms. 2,000-3,000 ppm - Dangerous, less than 1/2 hour exposure can be fatal. 5,000-10,000 ppm - Serious edema, strangulation, asphyxia, rapidly fatal. 10,000 ppm - Immediately fatal. It is recommended that: A clean, five-gallon water supply is attached to the nurse tank as required by federal and state regulation. At least five gallons of easily-accessible clean water is in the vehicle used to tow an anhydrous ammonia nurse tank as recommended by the University of Minnesota Extension Series. A 16-ounce water bottle is on the person for immediate access to flush any areas of the body exposed to anhydrous ammonia. It is recommended that protective gloves, boots, slicker and/or pants and jacket, and chemical-splash goggles that are impervious to anhydrous ammonia are worn at all times. ANYONE BURNED OR OVERCOME BY AMMONIA SHOULD SEEK IMMEDIATE EMERGENCY MEDICAL ASSISTANCE. APPENDIX A 35

38 CHARACTERISTICS OF ANHYDROUS AMMONIA Under normal atmospheric conditions, anhydrous ammonia is a gas. It is lighter than air, colorless*, and has a characteristic sharp odor. The chemical formula for ammonia is NH 3, which means that in every molecule of ammonia, there are three hydrogen atoms for each nitrogen atom. Since a nitrogen atom is 14 times heavier than a hydrogen atom, ammonia contains 82% nitrogen by weight. The pressure required to liquefy ammonia gas varies with temperature (boiling point). The density of liquid ammonia also varies a a function of temperature. Some of this information is illustrated in the following table. Figure 15 NURSE TANK NURSE TANK POUNDS PER CUBIC POUNDS PER CUBIC O TEMPERATURE F PRESSURE (PSI) FOOT NH3 FOOT NITROGEN *The white cloud seen when liquid ammonia is released into the atmosphere is actually water condensed from the air. 36 APPENDIX A

39 APPENDIX B SYSTEM CAPACITY CONSIDERATIONS Below recommendations provide information to help increase the maximum flow rate of the applicator system. There are two different types of heat exchangers sold by DICKEY-John: 1. Continental Super Flow (Table 1 refers to NH 3 flow rates that can be achieved using a Super Flow System. 2. Thermal Transfer Unit (TTU) (Table 2 refers to NH 3 flow rates that can be achieved using a thermal transfer unit. CONTINENTAL SUPER FLOW The Continental Super Flow Assembly system allows for faster runs at lower tank pressures. The system can attain flow rates up to 9,600 lbs/hr. It contains standard 1 1/4 inch plumbing and is compatible with the N-Serve nitrogen stabilizer. It features interchangeable orificed hose barbs for constant 2% or less vapor bleed off. To ensure the highest possible flow rates, your applicator plumbing must be sized properly. The following is a guideline for transfer of NH 3 from the nurse tank to the applicator. Table 1 (Super Flow System) Lbs/Hour Plumbing Size 0-3,600 1 inch feed line and breakaway 3,600-6, /4 inch feed line and breakaway 6,800 and up 1 1/2 inch feel line and breakaway THERMAL TRANSFER UNIT The control console, control valve, and flow meter are capable of handling liquid anhydrous ammonia flow rates in excess of 7200 lbs/hr. Table 2, derived from field test data, provides a general guide in determining overall system capacity when using the Thermal Transfer Unit exchanger. Table 2 (Thermal Transfer Unit) Lbs of NH 3 up to 6800 up to 5400 up to 4200 System Requirements 1. Two nurse tanks, 1 inch plumbing or larger. 2. Applicator plumbing, 1 1/4 inch or larger. 3. Two thermal transfer units. 1. Two nurse tanks, 1 inch plumbing or larger. 2. Applicator plumbing, 1 1/4 inch or larger. 3. One thermal transfer unit. 1. One nurse tank, 1 inch plumbing or larger. 2. Applicator plumbing, 1 1/4 inch or larger. 3. One thermal transfer unit. APPENDIX B 37