CCS100 NH3 application manual - DICKEY-john

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 .............................................................................................. 10
Operate Mode ................................................................................................................................. 10
Setup Mode..................................................................................................................................... 10
Constants ........................................................................................................... 13
P, Pn, or F........................................................................................................................ 13
Application Rate............................................................................................................... 13
Application Rate +/- (Change On The Go)....................................................................... 13
Implement Width .............................................................................................................. 13
Density ............................................................................................................................. 13
Flow Sensor Constant ..................................................................................................... 14
Flush Flow Rate ............................................................................................................... 14
Bargraph Maximum Flow Rate (÷10) ............................................................................... 14
System Response............................................................................................................ 15
Ground Speed Calibration ............................................................................................... 15
Preparing For Operation ................................................................................... 17
Control Valve Stationary Check ....................................................................................... 17
Verifying Accuracy ........................................................................................................... 17
Application Rate Fine Tuning........................................................................................... 18
Operation ............................................................................................................ 21
Field Operation (All Constants Entered) .......................................................................... 21
Incremental Application Rate (Change On The Go) ........................................................ 22
Bargraph ......................................................................................................................................... 22
Flush Mode ..................................................................................................................................... 22
Display Messages............................................................................................................ 23
OFF .................................................................................................................................................
APER (Application Rate Error)........................................................................................................
Bargraph .........................................................................................................................................
4-Digit Display .................................................................................................................................
Flashing 4-Digit Display ..................................................................................................................
Checkmark ......................................................................................................................................
23
23
23
23
23
23
Flush Mode Manual Override .......................................................................................... 23
Troubleshooting................................................................................................. 25
Applicators ...................................................................................................................... 25
Anhydrous Ammonia Control System .............................................................................. 25
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)....................................................................................................
25
26
26
27
28
Service Notes ..................................................................................................... 31
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
i
TABLE OF CONTENTS
Appendix A ........................................................................................................ 33
Handling Anhydrous Ammonia ........................................................................................ 33
Physiological Responses to Ammonia Vapor.................................................................. 35
Characteristics of Anhydrous Ammonia .......................................................................... 36
Appendix B ........................................................................................................ 37
System Capacity Considerations..................................................................................... 37
Continental Super Flow ................................................................................................................... 37
Thermal Transfer Unit...................................................................................................................... 37
NH3 System Flow Rates ................................................................................................. 38
Operating Principles ........................................................................................................ 38
Recommendations........................................................................................................... 38
Appendix C ........................................................................................................ 41
Handling Trapped Anhydrous Ammonia.......................................................................... 41
Warranty.............................................................................................................. 45
ii
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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.
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.
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
1
OPERATOR’S MANUAL
2
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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.
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
SAFETY NOTICES 3
OPERATOR’S MANUAL
4 SAFETY NOTICES
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
INTRODUCTION 5
OPERATOR’S MANUAL
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
RADAR II
GROUND SPEED
SENSOR *
MAIN HARNESS
SWITCH
MODULE
OPTIONAL
LIFT
SWITCH
12V
BATTERY
FUSE
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
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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 SYSTEM
Refer to the following illustrations for typical placement of the control system
components in the anhydrous ammonia applicator system.
Figure 3
Anhydrous Ammonia Plumbing Schematic (Single Manifold System)
QUICK
DISCONNECT
COUPLING
ANHYDROUS
AMMONIA
SHUTOFF
VALVE
*ELECTRIC, MANUAL,
OR HYDRAULIC
THERMAL SHUTOFF VALVE
BLEEDER
PRESSURE
RELIEF
NURSE
TANK
SHUTOFF
TRANSFER
UNIT
CONTROL
VALVE
MANIFOLD
FLOW
METER
NURSE
TANK
BLEEDER
SAFETY
BREAK-AWAY
CONNECTOR
AMMONIA TRANSFER
HOSE (1" or 1-1/4" - 350psi)
CONTROL
CONSOLE
AMMONIA TRANSFER
HOSE (1" - 350psi)
IMPLEMENT
KNIVES (8)
SWITCH MODULE
LIFT SWITCH
(optional)
GROUND SPEED
SENSOR
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
*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
OPERATOR’S MANUAL
Figure 4
Anhydrous Ammonia Plumbing Schematic (Dual Manifold System) for Dj Thermal Transfer or Super Flow
IMPLEMENT
KNIVES (8)
SUPERFLOW
CONTROL
VALVE
FLOWMETER
*ELECTRIC, MANUAL,
OR HYDRAULIC
SHUTOFF VALVE
MANIFOLD
PRESSURE RELIEF
QUICK
DISCONNECT
COUPLING
ANHYDROUS
AMMONIA
SHUTOFF
VALVE
BLEEDER
PRESSURE
RELIEF
NURSE
TANK
SHUTOFF
THERMAL
TRANSFER
UNIT
CONTROL
VALVE
FLOW
METER
NURSE
TANK
BLEEDER
IMPLEMENT
KNIVES (8)
SAFETY
BREAK-AWAY
CONNECTOR
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
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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
30
10
A
B
C
70
50
D
E
F
G
90
H
I
J
USED WITH
VAPOR DETECTOR
BARGRAPH
SETUP
ON
4-DIGIT
DISPLAY
APER
POWER
SWITCH
OFF
A P P L I C AT I O N R AT E
OPER
APPLICATION
RATE ERROR
9
SETUP
0
DICKEY-john
R
DjCCS100
OPERATE MODE
OPERATE MODE
- RETURN TO TARGET APPLICATION RATE
- LOCK SYSTEM IN FLUSH MODE
- HOLD FOR 3 SECONDS TO ENTER SETUP
MODE
OPERATE MODE
SETUP MODE
SETUP MODE
- SELECT CONSTANT LOCATION
- HOLD FOR 3 SECONDS TO ENTER
OPERATE MODE
- DECREASES APPLICATION RATE
- SELECTS DIGIT
- POSITIONS DECIMAL POINT
- STARTS AND STOPS GROUND
SPEED CALIBRATION
- INCREASES APPLICATION
RATE
SETUP MODE
- SETS DIGIT VALUE
Figure 6
Switch Module
FLUSH
A
U
T
O
A
U
T
O
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 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.
CCS100 Anhydrous Ammonia Control
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SETUP 9
OPERATOR’S MANUAL
INITIAL POWER UP OF SYSTEM
The CCS100 Control System has two active modes:
•
•
NOTE: When power is turned ON, the
control system will always
power up in OPERATE mode.
9
0
Increment switch
OPERATE mode used during normal field operation
SETUP mode used to enter constants that describe the anhydrous
ammonia applicator to the control console.
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.
Decrement switch
OPER
SETUP
Operate switch
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
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
Figure 7
Constants Decal
ANHYDROUS AMMONIA
SPRAYER
SETUP
POS.
A
B
C
D
E
F
G
H
I
J
A
B
C
SETUP
POS.
A
B
C
D
E
F
G
H
I
J
CONSTANTS
P or Pn
APPLICATION RATE
APPLICATION RATE +/NOZZLE SPACING
NOZZLE CAPACITY PRESSURE
NOZZLE FLOW CAPACITY
FLUSH PRESSURE
CONVERSION FACTOR
ZERO PRESSURE CALIBRATION
SYSTEM RESPONSE
NOZZLE MONITOR SET
GROUND SPEED CALIBRATION
PRESSURE LIMITS SET
CONSTANTS
F
APPLICATION RATE
APPLICATION RATE +/IMPLEMENT WIDTH
DENSITY
FLOW SENSOR CONSTANT
FLUSH FLOW RATE (÷10)
BARGRAPH MAX. FLOW RATE (÷10)
SYSTEM RESPONSE
GROUND SPEED CALIBRATION
45790-2700
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
30
10
A
B
C
70
50
D
E
F
G
90
H
I
J
SETUP
ON
OFF
A P P L I C AT I O N R AT E
OPER
9
SETUP
DICKEY-john
0
R
DjCCS100
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.
CCS100 Anhydrous Ammonia Control
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SETUP 11
OPERATOR’S MANUAL
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
30
10
A
B
C
70
50
D
E
F
G
90
H
I
J
SETUP
ON
OFF
A P P L I C AT I O N R AT E
OPER
9
SETUP
DICKEY-john
0
R
DjCCS100
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.
12 SETUP
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.
CCS100 Anhydrous Ammonia Control
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OPERATOR’S MANUAL
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 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 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 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.
CCS100 Anhydrous Ammonia Control
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CONSTANTS 13
OPERATOR’S MANUAL
Refer to the following table to obtain the density of NH3 or Nitrogen at the
operating pressure of the nurse tank.
NURSE TANK
TEMPERATUREOF
NURSE TANK
PRESSURE (PSI)
-28
-8
6
16
26
34
42
50
58
68
77
86
96
105
115
0
10
20
30
40
50
60
75
90
110
130
155
185
215
250
POUNDS PER CUBIC
FOOT NH3
POUNDS PER CUBIC
FOOT NITROGEN
42.5
41.7
41.1
40.6
40.2
39.8
39.4
39.0
38.6
38.1
37.7
37.2
36.6
36.1
35.6
35.0
34.3
33.8
33.4
33.1
32.8
32.4
32.1
31.8
31.4
31.0
30.6
30.2
29.7
29.3
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 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 - 420
1” Valve - 1TTU - 520
1” Valve - 2TTU - 680
1 1/4” Valve - Super Flow System - 960
14 CONSTANTS
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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.
•
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.
•
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).
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
CONSTANTS 15
OPERATOR’S MANUAL
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
CCS100 Anhydrous Ammonia Control
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OPERATOR’S MANUAL
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.
CCS100 Anhydrous Ammonia Control
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PREPARING FOR OPERATION 17
OPERATOR’S MANUAL
5. To determine the amount of product applied per acre:
Tank weight at start (minus) tank weight at finish
acres covered
=
pounds of NH 3
applied per acre
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 x
desired lbs per acre
For example:
Tank weight at start
Tank weight at finish
Acres covered
Desired pounds per acre
100 = % error
4200 pounds
1900 pounds
10
200 actual nitrogen
4200 - 1900 = 230 pounds of NH per acre
3
10
230 lbs of NH 3 applied per acre x .82 = 188.6 lbs of actual nitrogen per acre
188.6 - 200 = -.057 x 100 = -5.7% error
200
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 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
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
1. Determine the new flow meter constant as follows:
APR
New Flowmeter Constant = (Old Spreader Constant) Desired
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
208
= 2.15 x .9615 = 2.067 or 2.07
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.
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
PREPARING FOR OPERATION 19
OPERATOR’S MANUAL
20 PREPARING FOR OPERATION
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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 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 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.
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATION 21
OPERATOR’S MANUAL
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)
9
0
Increment 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
Decrement switch
OPER
SETUP
Operate switch
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
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
DISPLAY MESSAGES
OFF
OPER
SETUP
Operate switch
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 NH3. 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 =
Where:
(APR)(MPH)(W)(.1212)
10
APR = Application Rate in lbs per acre
MPH = Vehicle Ground Speed in miles per hour
W = Implement width in feet
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATION 23
OPERATOR’S MANUAL
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
= 181.8
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.
24 OPERATION
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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.
Regulator screen plugged.
Clean screens.
Downstream Manual,
Hydraulic, or electrical valves
are closed.
Open valves.
Suspected inaccurate
Application Rate
Improper Application Rate
Constant entered - not
updated.
Check all constants for proper
values.
Incorrect field driving interval.
Measure and correct.
Field area larger or smaller
than used in determining
amount of product to use.
Recheck calculations.
Above capacity of system.
Reduce Ground Speed (refer
to APPENDIX B) for system
capacity considerations.
ANHYDROUS AMMONIA CONTROL SYSTEM
CONTROL CONSOLE WILL NOT TURN ON
Probable Cause:
1.
2.
3.
4.
Blown fuse.
Battery connections.
Damaged power cable.
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.
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
TROUBLESHOOTING 25
OPERATOR’S MANUAL
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 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.
26 TROUBLESHOOTING
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
TROUBLESHOOTING 27
OPERATOR’S MANUAL
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.
28 TROUBLESHOOTING
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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.
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
TROUBLESHOOTING 29
OPERATOR’S MANUAL
30 TROUBLESHOOTING
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
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
SERVICE NOTES 31
OPERATOR’S MANUAL
32 SERVICE NOTES
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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.
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
APPENDIX A 33
OPERATOR’S MANUAL
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
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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.
– 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.
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.
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
APPENDIX A 35
OPERATOR’S MANUAL
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 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
NURSE TANK
TEMPERATUREOF
NURSE TANK
PRESSURE (PSI)
-28
-8
6
16
26
34
42
50
58
68
77
86
96
105
115
0
10
20
30
40
50
60
75
90
110
130
155
185
215
250
POUNDS PER CUBIC
FOOT NH3
42.5
41.7
41.1
40.6
40.2
39.8
39.4
39.0
38.6
38.1
37.7
37.2
36.6
36.1
35.6
POUNDS PER CUBIC
FOOT NITROGEN
35.0
34.3
33.8
33.4
33.1
32.8
32.4
32.1
31.8
31.4
31.0
30.6
30.2
29.7
29.3
*The white cloud seen when liquid ammonia is released into the
atmosphere is actually water condensed from the air.
36 APPENDIX A
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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 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 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 NH3 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 - 6,800
1 1/4 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)
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
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.
APPENDIX B 37
OPERATOR’S MANUAL
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 RATES
All 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 PRINCIPLES
The 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.
RECOMMENDATIONS
1. 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.
38 APPENDIX B
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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 16
Super Flow Assembly
*Super Flow
Assembly
45790-3320A
* 1 1/4 to 1”
Elbow/Vapor
Discharge
Adaptor
1 1/4 x 4
Inch
Nipple
*Manual
Shutoff Valve
45790-3430
(Refer to Note 2 below)
1 1/4 Ball Valve
Control
45790-3380
Actator
Mounting Bracket
45790-3390
*Hose
Barb
Pressure
Relief
*Base Elbow
*Base Mounting
Plate
Hydraulic Shutoff
(Optional)
*Vapor Tubes
45790-3340
Bleeder
Valve
Flowmeter
45790-1610S1
1 1/4 Inch
Elbow
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.
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
APPENDIX B 39
OPERATOR’S MANUAL
40 APPENDIX B
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
APPENDIX C
HANDLING TRAPPED ANHYDROUS AMMONIA
The 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.
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.
NOTE: Contact Continental NH3
Products for Super Flow
Assembly usage guidelines:
130 Yorktown
Dallas, TX 75222
PH#1-800-537-5642
www.continentalnh3.com
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 17
Continental Super Flow System
Super Flow
Assembly
Trapped
Anhydrous
Existing
Regulator
NOTE: Remove existing regulator
for optimum system performance.
Recommended Shutoff
Valve (not supplied
by DICKEY-john)
Trapped
Anhydrous
Recommended
Shutoff Valve
(not supplied
by DICKEY-john)
Downstream
Upstream
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
APPENDIX C 41
OPERATOR’S MANUAL
Figure 18
Thermal Transfer Unit
TO NURSE
TANK
THERMAL TRANSFER
UNIT (TTU)
DISTRIBUTION
MANIFOLD
LIQUID
ANHYDROUS
AMMONIA
LIQUID
ANHYDROUS
AMMONIA
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.
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.
42 APPENDIX C
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
OPERATOR’S MANUAL
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.
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
APPENDIX C 43
OPERATOR’S MANUAL
44 APPENDIX C
CCS100 Anhydrous Ammonia Control
11001-1362A-200712
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
considered defective if it substantially fulfills the performance expectations. THE FOREGOING
WARRANTY
IS
EXCLUSIVE
AND
IN
LIEU
OF
ALL
OTHER
WARRANTIES
OF
MERCHANTABILITY, FITNESS FOR PURPOSE, AND OF ANY OTHER TYPE, WHETHER
EXPRESS OR IMPLIED. DICKEY-john neither assumes nor authorizes anyone to assume for it
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.
For DICKEY- john Service Department, call
1-800-637-3302 in either the U.S.A. or Canada
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
Copyright 2007 DICKEY-john Corporation
Specifications subject to change without notice.