TABLE OF CONTENTS - DICKEY-john Anhydrous Ammonia Control 11001-1362A-200712 ii TABLE OF CONTENTS Appendix A 33 Handling Anhydrous Ammonia 33

CCS100 Anhydrous Ammonia Control11001-1362A-200712

i

TABLE OF CONTENTS

Safety Notices ...................................................................................................... 3

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

Setup ..................................................................................................................... 9Initial Power Up Of System.............................................................................................. 10

Operate Mode ................................................................................................................................. 10Setup Mode..................................................................................................................................... 10

Constants ........................................................................................................... 13P, Pn, or F........................................................................................................................ 13Application Rate............................................................................................................... 13Application Rate +/- (Change On The Go)....................................................................... 13Implement Width.............................................................................................................. 13Density ............................................................................................................................. 13Flow Sensor Constant ..................................................................................................... 14Flush Flow Rate............................................................................................................... 14Bargraph Maximum Flow Rate (÷10) ............................................................................... 14System Response............................................................................................................ 15Ground Speed Calibration ............................................................................................... 15

Preparing For Operation ................................................................................... 17Control Valve Stationary Check....................................................................................... 17Verifying Accuracy ........................................................................................................... 17Application Rate Fine Tuning........................................................................................... 18

Operation ............................................................................................................ 21Field Operation (All Constants Entered) .......................................................................... 21Incremental Application Rate (Change On The Go) ........................................................ 22

Bargraph ......................................................................................................................................... 22Flush Mode ..................................................................................................................................... 22

Display Messages............................................................................................................ 23OFF................................................................................................................................................. 23APER (Application Rate Error)........................................................................................................ 23Bargraph ......................................................................................................................................... 234-Digit Display ................................................................................................................................. 23Flashing 4-Digit Display .................................................................................................................. 23Checkmark ...................................................................................................................................... 23

Flush Mode Manual Override .......................................................................................... 23

Troubleshooting................................................................................................. 25Applicators ...................................................................................................................... 25Anhydrous Ammonia Control System.............................................................................. 25

Control Console Will Not Turn On................................................................................................... 25APER Message Displayed, Alarm Sounds ..................................................................................... 26Control Valve Will Not Open In AUTO Mode While Moving Through The Field ............................. 26Fuse Blows When Replaced ........................................................................................................... 27Temporary Field Repair (Cables).................................................................................................... 28

Service Notes ..................................................................................................... 31


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TABLE OF CONTENTS

Appendix A ........................................................................................................ 33Handling Anhydrous Ammonia ........................................................................................ 33Physiological Responses to Ammonia Vapor.................................................................. 35Characteristics of Anhydrous Ammonia .......................................................................... 36

Appendix B ........................................................................................................ 37System Capacity Considerations..................................................................................... 37

Continental Super Flow ................................................................................................................... 37Thermal Transfer Unit...................................................................................................................... 37

NH3 System Flow Rates ................................................................................................. 38Operating Principles ........................................................................................................ 38Recommendations........................................................................................................... 38

Appendix C ........................................................................................................ 41Handling Trapped Anhydrous Ammonia.......................................................................... 41

Warranty.............................................................................................................. 45

OPERATOR’S MANUAL


1

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 (www.cdc.gov/nasd) and the Fertilizer Institute, 1015 18th Street, NW, Washington, DC 20036.

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.

REFER TO MATERIAL SAFETY DATA SHEETS (MSDS) AND OTHER PERTINENT SAFETY REQUIREMENTS ASSOCIATED WITH THE HANDLING AND APPLICATION OF ANHYDROUS AMMONIA (NH3) WITH A LOCAL ANHYDROUS AMMONIA SUPPLIER.

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2

OPERATOR’S MANUAL


SAFETY NOTICES 3

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.

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4 SAFETY NOTICES

OPERATOR’S MANUAL


INTRODUCTION 5

INTRODUCTION

SYSTEM DESCRIPTIONThe 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 1CCS100

OPERATOR’S MANUAL


6 INTRODUCTION

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 2Harnessing Diagram

PREPARING FOR INSTALLATION1. 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

12VBATTERY

FUSE

SWITCHMODULE

MAIN HARNESS

OPTIONALLIFTSWITCH

RADAR IIGROUND SPEEDSENSOR *

djCCS100CONSOLE

NOT USED

OPTIONALVAPORDETECTOR

FLOWMETER

CONTROLVALVE

IMPLEMENTHARNESS

OPERATOR’S MANUAL


INTRODUCTION 7

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 NH3 CONTROL SYSTEMRefer to the following illustrations for typical placement of the control system components in the anhydrous ammonia applicator system.

Figure 3Anhydrous Ammonia Plumbing Schematic (Single Manifold System)

NURSETANK

NURSETANKSHUTOFF

QUICKDISCONNECTCOUPLING

ANHYDROUSAMMONIASHUTOFFVALVE

BLEEDER

BLEEDER

SAFETYBREAK-AWAYCONNECTOR

AMMONIA TRANSFERHOSE (1" or 1-1/4" - 350psi)

PRESSURERELIEF

THERMALTRANSFERUNIT

CONTROLVALVE

FLOWMETER

*ELECTRIC, MANUAL,OR HYDRAULICSHUTOFF VALVE

MANIFOLD

AMMONIA TRANSFERHOSE (1" - 350psi)

IMPLEMENTKNIVES (8)

GROUND SPEEDSENSOR

LIFT SWITCH(optional)

SWITCH MODULE

CONTROLCONSOLE

*This Valve(s) is necessary to provide shutdown capabilityin the event of electrical failure.This Valve(s) may be partof the existing regulator. During operation, regulator shouldbe adjusted to full open position.

OPERATOR’S MANUAL


8 INTRODUCTION

Figure 4Anhydrous Ammonia Plumbing Schematic (Dual Manifold System) for Dj Thermal Transfer or Super Flow

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.

NURSETANK

NURSETANKSHUTOFF

QUICKDISCONNECTCOUPLING

ANHYDROUSAMMONIASHUTOFFVALVE

BLEEDER

BLEEDER

SAFETYBREAK-AWAYCONNECTOR

AMMONIA TRANSFERHOSE (1" or 1-1/4" - 350psi)

PRESSURERELIEF

THERMALTRANSFERUNIT

CONTROLVALVE

FLOWMETER


IMPLEMENTKNIVES (8)

MANIFOLD

GROUND SPEEDSENSOR

LIFT SWITCH(optional)

SWITCH MODULE

CONTROLCONSOLE

*This Valve(s) is necessary to provide shutdown capabilityin the event of electrical failure.This Valve(s) may be partof the existing regulator. During operation, regulator shouldbe adjusted to full open position.


IMPLEMENTKNIVES (8)

MANIFOLD

AMMONIA TRANSFERHOSE (1" - 350psi)

PRESSURE RELIEF

FLOWMETER

SUPERFLOW

CONTROLVALVE

OPERATOR’S MANUAL


SETUP 9

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 5Operator Controls

Figure 6Switch Module

SETUPPOSITIONIDENTIFIER

BARGRAPH

OPERATE MODE- DECREASES APPLICATION RATE

SETUP MODE- SELECTS DIGIT- POSITIONS DECIMAL POINT- STARTS AND STOPS GROUND

SPEED CALIBRATION

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- INCREASES APPLICATION

RATE

SETUP MODE- SETS DIGIT VALUE

10 30 50 70 90

A B C D E F G H I J

SETUP

APER

A P P L I C AT I O N R AT E

O P E R

S E T U P 0

9

DICKEY-john R D j C C S 1 0 0

ON

OFF

4-DIGITDISPLAY

DISPLAYED INSETUP MODE

USED WITHVAPOR DETECTOR

APPLICATIONRATE ERROR

POWERSWITCH

AUTO

AUTO

FLUSH

OFF

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 speedas reference.

FLUSH- Provides the control console with a command that

causes the control valve to open to a pre-programmedflowrate. Remains as long as the switch is held in FLUSH.

*No functions in SETUP mode.

OPERATOR’S MANUAL


10 SETUP

INITIAL POWER UP OF SYSTEMThe 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: When power is turned ON, the control system will always power up in OPERATE mode.

OPERATE MODE1. 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 MODERefer 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.

0

9

Increment switch

SETUP

OPER

Operate switch

Decrement switch

OPERATOR’S MANUAL


SETUP 11

Figure 7Constants Decal

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 8Setup Mode

8. 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.

SPRAYER

SETUPPOS.

CONSTANTS

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

SETUPPOS.

CONSTANTS

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

45790-2700

10 30 50 70 90

A B C D E F G H I J

SETUP


O P E R

S E T U P 0

9


ON

OFF

OPERATOR’S MANUAL


12 SETUP

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 9Setup Mode - 4 Digits

11. 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.

SETTING INDIVIDUAL DIGITS AND DECIMAL TO DISPLAY THE DESIRED VALUE OF THE 4-DIGIT CONSTANT

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.

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.

10 30 50 70 90

A B C D E F G H I J

SETUP


O P E R

S E T U P 0

9


ON

OFF

OPERATOR’S MANUAL


CONSTANTS 13

CONSTANTS

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 FSelect F for anhydrous ammonia application.

APPLICATION RATEThe 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 NH3 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 WIDTHThe Implement Width Constant is the width of the applicator measured in feet (meters). The decimal point can be positioned as required.

DENSITYThe Density Constant is the product weight in pounds (kilograms) per cubic foot (liter) of NH3 or the weight in pounds (kilograms) of nitrogen contained in one cubic foot (liter) of NH3. The decimal point can be positioned as required.

IMPORTANT: If the Application Rate Constant is selected to be in pounds of NH3 per acre, the density must be in pounds per cubic foot NH3. 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.

SETUP

OPER

Operate switch

OPERATOR’S MANUAL


14 CONSTANTS

Refer to the following table to obtain the density of NH3 or Nitrogen at the operating pressure of the nurse tank.

1. 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 CONSTANTThe 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 RATEThe 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 - 420

1” Valve - 1TTU - 520

1” Valve - 2TTU - 680

1 1/4” Valve - Super Flow System - 960

NURSE TANK NURSE TANK POUNDS PER CUBIC POUNDS PER CUBICTEMPERATURE F PRESSURE (PSI) FOOT NH FOOT NITROGEN

-28 0 42.5 35.0-8 10 41.7 34.36 20 41.1 33.8

16 30 40.6 33.426 40 40.2 33.134 50 39.8 32.842 60 39.4 32.450 75 39.0 32.158 90 38.6 31.868 110 38.1 31.477 130 37.7 31.086 155 37.2 30.696 185 36.6 30.2

105 215 36.1 29.7115 250 35.6 29.3

O3

OPERATOR’S MANUAL


CONSTANTS 15

To calculate the flow rate:

The decimal point can be positioned as required.

SYSTEM RESPONSEThe 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 CALIBRATIONThe 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.

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).

Fr= (APR)(MPH)(W) (.1212)

Where: Fr = Flow rate in lbs/hrAPR = Application Rate in lbs/acreMPH = Miles per hourW = Width of applicator in feet

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.

SETUP

OPER

Operate switch

OPERATOR’S MANUAL


16 CONSTANTS

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.

Decrement switch

OPERATOR’S MANUAL


PREPARING FOR OPERATION 17

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 10Valve Assembly (Without Motor Actuator Assembly)

VERIFYING ACCURACYAccuracy 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.

CONTROL

VALVE

COUPLING

CLOSED

POSITION

OPERATOR’S MANUAL


18 PREPARING FOR OPERATION

5. To determine the amount of product applied per acre:

6. To determine percent error:

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• 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 TUNINGIf, 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.

Tank weight at start (minus) tank weight at finishacres covered

=pounds of NHapplied per acre

3

Pounds of NH applied per acre x .82 = pounds of actual Nitrogen per acre3

Actual lbs per acre (minus) desired lbs per acredesired lbs per acre

x 100 = % error

For example:Tank weight at start 4200 poundsTank weight at finish 1900 poundsAcres covered 10Desired pounds per acre 200 actual nitrogen

4200 - 190010

= 230 pounds of NH per acre3

230 lbs of NH applied per acre x .82 = 188.6 lbs of actual nitrogen per acre3

188.6 - 200200

= -.057 x 100 = -5.7% error

OPERATOR’S MANUAL


PREPARING FOR OPERATION 19

1. Determine the new flow meter constant as follows:

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 = 200Actual APR = 208Old Flow Meter Constant = 2.15

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.

New Flowmeter Constant = (Old Spreader Constant)Desired APRActual APR

200208(2.15) = 2.15 x .9615 = 2.067 or 2.07

OPERATOR’S MANUAL


20 PREPARING FOR OPERATION

OPERATOR’S MANUAL


OPERATION 21

OPERATION

The CCS100 Anhydrous Ammonia Control System in the normal operating mode will display the pounds (kilograms) per acre (hectare) of Anhydrous Ammonia or Nitrogen applied.

Figure 11Control 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 NH3. 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 NH3. Fix the leak and recharge.

Do not weld on any system parts that might contain residual NH3 liquid or vapor.

OPERATOR’S MANUAL


22 OPERATION

5. To begin applying NH3, 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 NH3 and the Thermal Transfer Unit to begin functioning (cooling the NH3).

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 NH3 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)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).

BARGRAPHThe 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 MODEThe 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.

0

9

Increment switch

Decrement switch

SETUP

OPER

Operate switch

OPERATOR’S MANUAL


OPERATION 23

DISPLAY MESSAGES

OFFWhen 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.

BARGRAPHIndicates current pounds per hour (Kg/hr) being applied.

4-DIGIT DISPLAYIndicates actual application rate in pounds per acre (Kg/hectare).

FLASHING 4-DIGIT DISPLAY+/- application rate has been activated.

CHECKMARKDisplays when the Vapor Detector (optional) detects a threshold level of vapor in the flow of liquid NH3. The alarm will sound for approximately 3 seconds.

FLUSH MODE MANUAL OVERRIDEAll 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.

Where: APR = Application Rate in lbs per acre

MPH = Vehicle Ground Speed in miles per hour

W = Implement width in feet

Flush Flow Rate =(APR)(MPH)(W)(.1212)

10

SETUP

OPER

Operate switch

OPERATOR’S MANUAL


24 OPERATION

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:

Enter 181.8 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.

FFR=(150)(5)(20)(.1212)

10= 181.8

OPERATOR’S MANUAL


TROUBLESHOOTING 25

TROUBLESHOOTING

Before performing troubleshooting, the applicator must be drained of all Anhydrous Ammonia. Refer to APPENDIX C for draining procedures.

APPLICATORS

ANHYDROUS AMMONIA CONTROL SYSTEM

CONTROL CONSOLE WILL NOT TURN ONProbable 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.

Symptom Probable Cause Corrective Action

APER message displayed, alarm sounds when attempting to apply Anhydrous Ammonia.

Regulator screen plugged.

Downstream Manual, Hydraulic, or electrical valves are closed.

Clean screens.

Open valves.

Suspected inaccurate Application Rate

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.

Check all constants for proper values.

Measure and correct.

Recheck calculations.

Reduce Ground Speed (refer to APPENDIX B) for system capacity considerations.

OPERATOR’S MANUAL


26 TROUBLESHOOTING

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 cut2. 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 NH3 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 NH3 at low pressure. Lack of frost does not always indicate a lack of NH3.

3. 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.

OPERATOR’S MANUAL


TROUBLESHOOTING 27

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 REPLACEDProbable 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

OPERATOR’S MANUAL


28 TROUBLESHOOTING

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 4.

4. 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.

OPERATOR’S MANUAL


TROUBLESHOOTING 29

Figure 12Recommended 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 13Applying 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 14Applying 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.

OPERATOR’S MANUAL


30 TROUBLESHOOTING

OPERATOR’S MANUAL


SERVICE NOTES 31

SERVICE NOTES

Contact the DICKEY-john Service Department for technical support at 1-800-637-3302. 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 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

OPERATOR’S MANUAL


32 SERVICE NOTES

OPERATOR’S MANUAL


APPENDIX A 33

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.

OPERATOR’S MANUAL


34 APPENDIX A

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.

OPERATOR’S MANUAL


APPENDIX A 35

PHYSIOLOGICAL RESPONSES TO AMMONIA VAPORConcentration 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.– 20-50 ppm - Readily detectable odor.– 50-100 ppm - No discomfort or impairment of health for prolonged

exposure.– 150-200 ppm - General discomfort and eye tearing; no lasting effect

on short exposure.– 400-700 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.


ANYONE BURNED OR OVERCOME BY AMMONIA SHOULD SEEK IMMEDIATE EMERGENCY MEDICAL ASSISTANCE.

OPERATOR’S MANUAL


36 APPENDIX A

CHARACTERISTICS OF ANHYDROUS AMMONIAUnder 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 NH3, 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

*The white cloud seen when liquid ammonia is released into the atmosphere is actually water condensed from the air.

NURSE TANK NURSE TANK POUNDS PER CUBIC POUNDS PER CUBICTEMPERATURE F PRESSURE (PSI) FOOT NH FOOT NITROGEN

-28 0 42.5 35.0-8 10 41.7 34.36 20 41.1 33.8

16 30 40.6 33.426 40 40.2 33.134 50 39.8 32.842 60 39.4 32.450 75 39.0 32.158 90 38.6 31.868 110 38.1 31.477 130 37.7 31.086 155 37.2 30.696 185 36.6 30.2

105 215 36.1 29.7115 250 35.6 29.3

O3

OPERATOR’S MANUAL


APPENDIX B 37

APPENDIX B

SYSTEM CAPACITY CONSIDERATIONSBelow 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 NH3 flow rates that can be achieved using a Super Flow System.

2. Thermal Transfer Unit (TTU) (Table 2 refers to NH3 flow rates that can be achieved using a thermal transfer unit.

CONTINENTAL SUPER FLOWThe 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 NH3 from the nurse tank to the applicator.

Table 1 (Super Flow System)

THERMAL TRANSFER UNITThe 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/Hour Plumbing Size

0 - 3,600 1 inch feed line and breakaway

3,600 - 6,800 1 1/4 inch feed line and breakaway

6,800 and up 1 1/2 inch feel line and breakaway

Lbs of NH3 System Requirements

up to 6800 1. Two nurse tanks, 1 inch plumbing or larger.2. Applicator plumbing, 1 1/4 inch or larger.3. Two thermal transfer units.

up to 5400 1. Two nurse tanks, 1 inch plumbing or larger.2. Applicator plumbing, 1 1/4 inch or larger.3. One thermal transfer unit.

up to 4200 1. One nurse tank, 1 inch plumbing or larger.2. Applicator plumbing, 1 1/4 inch or larger.3. One thermal transfer unit.

OPERATOR’S MANUAL


38 APPENDIX B

Notes:

1. Data given for nurse tank pressure of 120 psi. Flow rate values at 60 psi should be reduced by approximately one third.

2. One inch plumbing may be suitable for lower flow rate requirements.3. Plumbing size and tank pressure determine maximum flow rates.

Increased or decreased hose size and/or increased or decreased tank pressure will effect maximum flow rates.

NH3 SYSTEM FLOW RATESAll maximum flow rates listed are at 110 psi tank pressure. To account for application in cold conditions where tank pressures will be significantly lower, use the following conversion when sizing an NH3 system. Approximately 1/3 of the total system capacity is lost at one half of the tank pressure.

Example: 42.5 ft x 6 mph x 200 lbs. NH3 x 0.1212 = 6181 lbs/hr

6181 lbs/hr x 1.335 = 8251 lbs/hr

Based on the calculation above, you would need a system with at least 8251 lbs/hr capacity to put on the required amount at 55 psi tank pressure or in this instance, a Continental Super Flow system rated at 9600 lbs/hr maximum flow rate.

OPERATING PRINCIPLESThe flow based control system will accurately control the application of NH3 as long as liquid NH3 is flowing through the flow meter. As illustrated in (Figure 17), vapor bubbles are formed in the liquid as it leaves the nurse tank. This vaporization occurs as a result of the pressure loss required to push liquid NH3 out of the nurse tank. Furthermore, any pressure losses between the tank and the flow metering point can only generate more vapor.

The Heat Exchanger Unit, inserted just before the flow meter, transfers heat from the warmer incoming liquid-vapor mix to the cooler outgoing liquid-vapor mix. This heat transfer allows incoming vapor to cool and condense into liquid, thus providing a purse liquid flow to be metered.

In practice, doubling flow rate will increase the volume of vapor generated by factors of 4 to 8 times. This means 4 to 8 times more thermal capacity is needed from the thermal transfer unit.

In terms of cost and size, this is not an overly desirable solution. It is far more cost effective to minimize the generation of vapor before the material reaches the thermal transfer unit and flow meter. The following recommendations address this issue.

RECOMMENDATIONS1. Use 1 1/4 inch or larger hoses, pipe fittings, and valves between the

nurse tank and the thermal transfer unit.2. Do not coil up excess supply hoses; use only the lengths required.3. Use 1 1/4 inch or larger breakaway couplers.

OPERATOR’S MANUAL


APPENDIX B 39

4. Do not use elbows if a straight coupler can be used.5. Keep any filter screens in the system cleaned.6. Provide adequately sized downstream plumbing to prevent excessive

manifold pressure.7. Manifolds typically require 10 psi or greater to provide uniform

distribution.8. Fill the center hole of the heat exchanger unit with fiberglass insulation.9. If an old flow regulator is left in the system, be certain that it is full open.

10. Do not expect all nurse tanks to work equally.11. Keep knife injector tubes from plugging.12. Replace collapsed, soft, or kinked hoses.13. When two nurse tanks are used, tee the feed hoses together just

before the heat exchanger unit.14. Nurse tanks with temperatures above air temperature will provide

greater flow rates than those with temperatures below air temperature.

Use a 1 1/4 inch breakaway coupler for each feed hose.

Figure 16Super Flow Assembly

* 1 1/4 to 1” Elbow/Vapor

DischargeAdaptor

1 1/4 x 4Inch

Nipple

PressureRelief

*Base Elbow

*Base MountingPlate

BleederValve

*ManualShutoff Valve45790-3430

*HoseBarb

*Super FlowAssembly

45790-3320A

1 1/4 Ball ValveControl

45790-3380Actator

Mounting Bracket45790-3390

*Vapor Tubes45790-3340

Flowmeter45790-1610S1

1 1/4 InchElbow

(Refer to Note 2 below)

Hydraulic Shutoff(Optional)

Notes:1. Items marked with an asterisk (*) are part of the Super Flow package. Remaining items are included in a separate hardware kit.

2. If using a hydraulic shutoff valve, it must be located between the control valve and the vapor discharge adaptor. For safety reasons, it is highly recommended that a hydraulic shutoff valve (not provided) be installed.

OPERATOR’S MANUAL


40 APPENDIX B

OPERATOR’S MANUAL


APPENDIX C 41

APPENDIX C

HANDLING TRAPPED ANHYDROUS AMMONIAThe Super Flow Assembly is a manufactured product of Continental NH3 Products, therefore, the user should consult with the individual manufacturer’s guidelines regarding inspection, maintenance, and useful life of any component parts.

NOTE: Contact Continental NH3 Products for Super Flow Assembly usage guidelines: 130 Yorktown Dallas, TX 75222 PH#1-800-537-5642 www.continentalnh3.com

DICKEY-john does not warrant products that are not manufactured by DICKEY-john and does not make any definitive representation regarding the useful lives of those parts. It is recommended to conduct daily inspections of hoses for kinks and defects, as well as full inspection and maintenance of those hoses and valves.

Zero pressure in your applicator system does not mean that all anhydrous ammonia is out of the system. Liquid anhydrous ammonia may still be present. Frost on any part or component of the system is a positive indication of liquid anhydrous ammonia at low pressure. However, the lack of frost does not indicate a lack of anhydrous ammonia, particularly in heavy-duty hoses.

IMPORTANT: It is recommended that upstream and downstream check valves are installed. Refer to the appropriate piping/plumbing component manufacturer and anhydrous ammonia literature for further details.

Figure 17Continental Super Flow System

ExistingRegulatorNOTE: Remove existing regulatorfor optimum system performance.

Recommended Shutoff Valve(not supplied by DICKEY-john)

Super FlowAssembly

Recommended Shutoff Valve (not supplied by DICKEY-john)

Upstream

TrappedAnhydrous

TrappedAnhydrous

Downstream

OPERATOR’S MANUAL


42 APPENDIX C

Figure 18Thermal Transfer Unit

IMPORTANT: Before installation, and if it becomes necessary to replace any component of the control system, the applicator must be drained of all anhydrous ammonia.

To drain the application (for installation, storage, or maintenance):1. Disconnect the nurse tank from the applicator.2. Lower the applicator. While pulling it through the field, open the

regulator valves or place the control system in AUTO. If manifold shutoff valves are present, open them.

3. Continue driving until the applicator system shows zero pressure. Applicator knives do not “smoke” when raised out of the ground.

4. Open all bleed-off valves of the system to allow vapors to dispense.If liquid anhydrous ammonia is present (after a short period of time) frost may form on metallic components and a temperature change can be detected on hoses.

5. Clear the hoses by raising the low spots.

If liquid anhydrous ammonia is present, a discharge will be visible through the applicator knives. Make certain you are on the upwind side of the applicator.

Liquid anhydrous ammonia will evaporate from a depressurized (all valves open) system. This evaporation may take 1 day, 2 days, or several weeks depending on temperature and weather conditions. After a period of time, check the temperature from top to bottom of the heat exchanger unit. If a temperature difference is detected, liquid anhydrous ammonia is still present and additional time is required for evaporation. If no temperature difference is detectable, the system can be stored.


TO NURSETANK

LIQUIDANHYDROUSAMMONIA

THERMAL TRANSFERUNIT (TTU)

DISTRIBUTIONMANIFOLD

LIQUIDANHYDROUSAMMONIA

OPERATOR’S MANUAL


APPENDIX C 43

To remove or replace components (after completing previous steps):6. Look for frost on the Heat Exchanger and hoses. If none is seen, check

the temperature of the hoses in question, particularly at low spots and the Heat Exchanger. If a change in temperature is detected along a hose or from top to bottom, this indicates that liquid anhydrous ammonia is present.

7. Clear the hoses by raising the low spots. If liquid anhydrous ammonia is present, a discharge will be seen through the applicator knives. Make certain you are on the upwind side of the applicator.

8. For replacement of flow meter, control valve, or Heat Exchanger, it is recommended that the Heat Exchanger be completely filled with water. With protective clothing and goggles in place, carefully remove one of the pressure relief valves on the Heat Exchanger. Install a 1/4 inch pipe nipple (4-6 inches in length) in the pressure relief valve port. Slide a garden hose over the 1/4 inch pipe nipple and clamp it in place.

IMPORTANT: When water mixes with anhydrous ammonia, boiling will occur and may cause vapor and water to shoot out the knives and the nurse tank hose end. Make sure the nurse tank hose is pointed in a safe direction. If water runs out of the nurse tank hose before both chambers of the Super Flow are filled, it may be necessary to close the shutoff valve on the hose.

Make certain you are a safe distance on the upwind side and that no person or animal is immediately downwind.

9. Slowly turn on the water. Allow the applicator system and the Super Flow to completely fill with water. Turn off the water and remove the garden hose. Disassemble the components as required.

10. Reinstall the pressure relief valve.

OPERATOR’S MANUAL


44 APPENDIX C

Copyright 2007 DICKEY-john Corporation Specifications subject to change without notice.

Dealers have the responsibility of calling to the attention of their customers the following warranty prior to acceptance of an order from their customer for any DICKEY-john product.

DICKEY-john® WARRANTY DICKEY-john warrants to the original purchaser for use that, if any part of the product

proves to be defective in material or workmanship within one year from date of original

installation, and is returned to DICKEY-john within 30 days after such defect is discovered,

DICKEY-john will (at our option) either replace or repair said part. This warranty does not apply

to damage resulting from misuse, neglect, accident, or improper installation or maintenance; any

expenses or liability for repairs made by outside parties without DICKEY-john’s written consent;

damage to any associated equipment; or lost profits or special damages. Said part will not be

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any other obligation or liability in connection with said part and will not be liable for

consequential damages. Purchaser accepts these terms and warranty limitations unless the

product is returned within fifteen days for full refund of purchase price.

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Headquarters: 5200 Dickey-john Road, Auburn, IL 62615 TEL: 217-438-3371, FAX: 217-438-6012, WEB: www.dickey-john.com Europe: DICKEY-john Europe S.A.S, 165, boulevard de Valmy, 92700 – Columbes – France TEL: 33 (0) 1 41 19 21 80, FAX: 33 (0) 1 47 86 00 07 WEB: www.dickey-john.eu

Documents

TABLE OF CONTENTS - DICKEY-john Anhydrous Ammonia Control 11001-1362A-200712 ii TABLE OF CONTENTS Appendix A 33 Handling Anhydrous Ammonia 33