mt-9000 tm - micro-trak

Reference Manualfor NH3 Control

MT-9000Automatic Spray Rate Controller

TM

2

Automatic Liquid, Anhydrous and Dry Rate Control System

RefeRence ManualThe MT-9000 Series is an electronic monitor and control system that can help you achieve maximum yields and operate more cost-effectively by providing the information you need to maintain proper application rates of liquid, anhydrous ammonia and dry material. The MT-9000 Series is designed for easy installation and operation. However, since each installation will vary depending on your equipment, please take time to familiarize yourself with this manual and the actual components before beginning. Following the procedures described in this manual will ensure proper performance and help avoid problems or questions once you are in the field.

This manual is written for the MT-9600 Model MT96-99-VR, which may be used for English, Metric or Turf measurement. Please read the manual carefully and follow the instructions as they apply to your usage.

If you do encounter a problem that cannot be corrected by reviewing this manual, consult your dealer or distributor, or contact a Micro-Trak technician for assistance.

Toll free in u.S. or canada: (800) 328-9613 or (507) 257-3600fax: (507) 257-3001

www.micro-trak.com • [email protected]

P.O. Box 99111 east leRay avenue

eagle lake, Mn 56024-0099

©1999 • Micro-Trak Systems, Inc. • Printed in the u.S.a.

MT-9000™Series

3

Micro-Trak® WarrantyMicro-Trak (herein “Seller”) warrants to the original purchaser (herein “Buyer”) that, if any product or part of the product (herein “part”) proves to be defective in material or workmanship, upon inspection and examination by Seller, within one (1) year from the original date-of-purchase, and is returned to Seller with dated proof-of-purchase, transportation prepaid, within thirty (30) days after such defect is discovered, Seller will, at their option and sole discretion, either repair or replace said part, except that the warranty for expendable parts, including but not limited to, light bulbs and batteries shall be thirty (30) days from the original date-of-purchase. Said warranty is valid only when the part has been installed, operated and maintained in strict accordance with the procedures outlined in the manual. Any damage or failure to said part resulting from abuse, misuse, neglect, accidental or improper installation or maintenance, unauthorized modification, use with other products or attributable to acts of God, as determined solely by the Seller, will invalidate the warranty. Said part will not be considered defective if it substantially fulfills the performance specification. Buyer shall be responsible for all maintenance services, if any, all in strict accordance with the procedures outlined in the manual. The warranty does not include labor, installation, replacement parts or repairs, delivery of replacement parts or repairs or time and travel. Said warranty is nontransferable.

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. The Seller’s liability, whether in contract, in tort, under any warranty, in negligence or otherwise, shall not exceed the return of the amount of the purchase price paid by the Buyer, and under no circumstance shall the Seller be liable for special, indirect or consequential damages. Seller neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said part. No action, regardless of form, arising out of the transactions under this agreement may be brought by the Buyer more than one (1) year after the cause of action has occurred.

Seller agrees to extend the term of the foregoing warranty period should the Buyer return completed warranty registration information, with dated proof-of-purchase, to the Seller within one (1) year from the original date-of-purchase. All conditions and limitations of said foregoing warranty, except the term of said foregoing warranty, shall apply. Said term shall be extended to a total of three (3) years from the original date-of-purchase on display consoles and network communication modules, as defined by Seller, and said term shall be extended to a total of two (2) years from the original date-of-purchase on all other parts, except that the warranty for expendable parts, including but not limited to, light bulbs and batteries shall be thirty (30) days from the original date-of-purchase and except that the warranty for parts manufactured by someone other than the Seller, including but not limited to, shutoff and control valves, DGPS receivers, memory cards and drives, mapping software, flowmeters and pressure sensors shall be one (1) year from the original date-of-purchase.

Buyer accepts these terms and warranty limitations unless the product is returned to Seller, via proper distribution channels and approved return authorization, with dated proof-of-purchase, transportation prepaid, within fifteen (15) days from the date-of-purchase for refund of the purchase price.

Units under warranty should be sent prepaid, with dated proof-of-purchase, within thirty (30) days of discovering defect, to the address below:

Mail and uPS:Micro-Trak Systems, Inc.

aTTn: Service DepartmentP.O. Box 99

111 east leRay avenueeagle lake, Mn 56024-0099

extended Warranty OptionIt’s simple! Just complete the enclosed registration card(s) for this product

and mail it in and we’ll extend your warranty for up to three years*, at no additional charge.

MaIl In yOuR RegISTRaTIOn caRD TODay!Registration card information is for internal use only.

* Some limitations apply. See warranty statement for details.

At Micro-Trak Systems, we believe a product that delivers quality and performance at a low cost is what is needed to help today’s operator and the operator of the future.

It is our goal to provide operators with a line of electronic equipment that will help build and maintain an efficient and profitable operation.

We thank you for your purchase and hope that we can be of service to you in the future.

Micro-Trak Systems, Inc.

4

Table of ContentsWarranty...................................................................................................................................................................................... 3Table of contents ...................................................................................................................................................................4-5component Parts and assembly Hardware ......................................................................................................................6-7Installation .............................................................................................................................................................................8-18 Required Tools .............................................................................................................................................................................................8 Mounting the Display Console ..............................................................................................................................................................8 Electrical Installation .................................................................................................................................................................................8 Speed Sensor Installation ................................................................................................................................................................. 9-10 Magnets .................................................................................................................................................................................................9 Attaching Magnets .........................................................................................................................................................................10 Connecting the Speed Sensor Cable ...............................................................................................................................................10 Connecting the Run/Hold Sensor Cable .........................................................................................................................................11 Speed Sensor Options ...........................................................................................................................................................................11 NH350 Kit Installation ............................................................................................................................................................................12 Equalizer Kit Installation .......................................................................................................................................................................13 Raven Super Cooler Kit Installation ..................................................................................................................................................14 NH3500 Vapor Tube Installation ........................................................................................................................................................15 Raven Super Cooler Vapor Tube Installation ................................................................................................................................15 Installing Pressure Sensor ....................................................................................................................................................................16 Electrical ......................................................................................................................................................................................................16 MT-900 NH3 System Diagram.............................................................................................................................................................17 MT-9000 NH3 Wiring Diagram ...........................................................................................................................................................18console functions ................................................................................................................................................................... 19calibration .......................................................................................................................................................................... 20-29 Introduction to Calibration ..................................................................................................................................................................20 “Special” Calibration .........................................................................................................................................................................20-23 Entering “Special” Calibration Values ................................................................................................................................20-23 Units of Measure ......................................................................................................................................................................20 Material Type, Servo Type .....................................................................................................................................................21 Servo Polarity, Boom Shutoff Valve Type, Boom Valve Setting, Tank Alarm Set Point, Tank Size .............22 Exiting “Special” Calibration ................................................................................................................................................23 Special Factory-loaded Calibration Values .....................................................................................................................23 Standard Calibration ........................................................................................................................................................................24-29 Entering Standard Calibration ...................................................................................................................................................24 Entering Standard Calibration Values ...............................................................................................................................24-29 Target Rate, Adjust Rate ........................................................................................................................................................24 Boom Width, Min Flow ..........................................................................................................................................................25 Flowmeter, Distance ...............................................................................................................................................................26 Determining Wheel Circumference .........................................................................................................................................26 Fine-tuning Speed/Distance Calibration ...............................................................................................................................27 Fine-tuning Flowmeter Calibration..........................................................................................................................................28 Standard Factory-loaded Calibration ......................................................................................................................................29 Exiting Standard Calibration .......................................................................................................................................................29

5

Table of Contents (cont)Operation ............................................................................................................................................................................ 30-32 Display Area, Power Switch, Auto/Man/Hold Switch, “+/- Switch, Boom Switches .......................................................30 Rate Button, Tank Button, Test Button, Reset Button ................................................................................................................31 Rotary Dial ..................................................................................................................................................................................................31 Warning Device, Light Sensor, Variable Rate Technology .......................................................................................................31 Resetting System Counters ..................................................................................................................................................................32 Field Operation ........................................................................................................................................................................................32Troubleshooting ................................................................................................................................................................ 33-37 General ........................................................................................................................................................................................................33 Checking Individual Components .....................................................................................................................................................34 Checking Console Inputs ......................................................................................................................................................................35 Plumbing Panel Harness .......................................................................................................................................................................36 Flowmeter Cleaning and Assembly ..................................................................................................................................................37appendices ......................................................................................................................................................................... 38-43 Appendix A: Optional Speed Sensor Mounting Installation .............................................................................................39-40 Appendix B: Conversion Chart ...........................................................................................................................................................41 Appendix C. Replacement Parts ........................................................................................................................................................42 Appendix D: Glossary of Terms ..........................................................................................................................................................43

Terminal KitP/N 13270

Speed Sensor Kit P/n 01531Including items A-G, below:

5’ Hall-effect Flow Sensor Cablewith Threaded Sensor Connector

Green Body

A. 5’ Hall-effect Speed/Flow Sensor Cable P/N 13096

C. 15’ 3-Pin ExtensionCable M/P 150

P/N 13207B. 14” Nylon Cable Ties (10)

P/N 12910F. Magnet Clips (6)

P/N 10080

G. Hardware BagP/N 13251

D. Speed Sensor Mounting Bracket

P/N 10013

E. Magnets (6) P/N 12069

(2 in hardware bag)

MT-9000Automatic Spray Rate Controller

Reference Manualfor NH3 Control

TM

Reference ManualP/N 13797

MT-9000 Series ConsoleP/N 13253

10’ 10-Pin M/PMain Harness

P/N 13276

FIELD AREA

TOTAL AREA

SPEED

TARGET RATE

ADJUST RATE

BOOM WIDTH

FLOW RATE

TOTAL FLOW

FIELD FLOW

MIN. FLOW

FLOWMETER

DISTANCE

RATE 1 RATE 3RATE 2 RESETTESTTANK

BOOMSON

OFF

AUTO

MAN

HOLD

POWER ON

OFF

20’ 3-Pin M/P Power Harness P/N 13221

15’ 10-Pin M/P Extension Cable P/N 13222

E D C B A

E D C B A

A B C D E

A B C

D E A B C D E

A

14” Nylon Cable Ties P/N 12910

Console Mount KitP/N 13254

6

Component Parts and Assembly HardwareBefore beginning installation, check the carton contents for the following items:

NH3500 Kit • P/N 01120

Equalizer Kit • P/N 01125

Control Kit for Raven Super Cooler • P/N 01121

7

Component Parts and Assembly Hardware (cont)

FIELD AREA

TOTAL AREA

SPEED

TARGET RATE

ADJUST RATE

BOOM WIDTH

FLOW RATE

TOTAL FLOW

FIELD FLOW

MIN. FLOW

FLOWMETER

DISTANCE

RATE 1 RATE 3RATE 2 RESETTESTTANK

BOOMSON

OFF

AUTO

MAN

HOLD

POWER ON

OFF

8

InstallationMounting the Display Console

Tools needed to Install MT-9000• Screwdrivers • Pliers• Set of Wrenches • Wire Cutter• Electric Drill and Bits • Hacksaw• 12-Volt Test Light • Center Punch• Bench Vise • Hammer

Select a mounting location which seems most workable, and that best fits your needs. It should be convenient to reach and highly visible to the operator. DO nOT InSTall In a POSITIOn THaT OBSTRucTS THe vIeW Of THe ROaD OR WORK aRea. Whenever possible, avoid locations that expose the console to direct sunlight, high temperature, strong chemicals or rain.

Place the mounting bracket in the selected location, mark holes, drill 1/4” (7 mm) holes and mount bracket with bolts, lockwashers and nuts provided. (If bolts are not practical, use self-tapping screws.) See Illustration 1.

Place the console in the “U” bracket and install the console knobs through the bracket, placing a rubber washer over the threaded stud. Position the console to the proper viewing angle and tighten the knobs securely. See Illustration 1.

Illustration 1

Electrical InstallationThe MT-9000 Series must be connected to a 12-volt DC elec-tri cal system. Power is connected directly to the battery. The MT-9000 Series has an ON/OFF switch on the console to turn the power off when the system is not being used.

Locate the power cable harness and connect to the mating connector on the console. Connect the blue chassis ground wire to a good frame ground. See Il lus tra tion 2. Make sure there is good metal-to-metal contact. Route the power cable from the console to the battery. Cut excess length. In routing cable to battery, avoid ar eas where the ca ble may be subjected to abra sion or ex ces sive heat. Install the in-line fuse provided with the kit as illustrated, on the white wire, to protect the circuit. Connect the WHITE wire (hot) to the positive battery terminal. At tach the BLACK wire (ground) to a screw or bolt on the equipment frame. See Il lus tra tion 2. Be sure there is good metal-to-metal con-tact.

Your MT-9000 Series is equipped with an elec tronic mem o ry which does not re quire a con stant supply of pow er to re tain daily totals or calibration val ues. The advantage with this type of memory is that it conserves battery power and will not dis charge the vehicle’s battery when equipment is not in use.

Illustration 2

ChassisGround(black)

Ground

20.0 Amp in-line Fuse RequiredHot

(White)

C B A

nOTe: for negative ground Systems Only

Installation (cont)

Speed Sensor Installationlocate the following Parts• Speed Sensor Cable• Mounting “L” Bracket• Magnet Clips• Magnets• Cable Ties

PleaSe nOTe: If you have purchased a Trak-Star speed sensor, disregard the following section on magnetic speed sensors and install the Trak-Star as described in the instructions included with the unit. (Please refer to page 12 for additional speed sensor options.)

MagnetsPlease read the following information about magnet spacing and polarity.

The number of magnets that must be used depends on the size of your tire and where you mount the sensor. The general rule for tractor or implement wheels is one magnet for each wheel bolt (minimum of two, and always use an even number). For drive shafts or small wheels (ATV’s), a minimum of two magnets are required.

Some installations may require that more than two magnets be installed. To determine the number of magnets required, measure the distance traveled of one revolution of the sensor equipped wheel in inches (meters). Divide that measurement by 20 for English and Turf units, or by .5 for Metric units, and then round up to the nearest even number (always use an even number of magnets). That number will be the minimum number of magnets required for the installation.

exaMPle In englISH/TuRf unITSIf your revolution measurement is 97 inches, dividing that number by 20 gives you a value of 4.85. Rounding 4.85 up to the nearest even number is 6. For this example, the minimum number of magnets required is 6.

exaMPle In MeTRIc unITSIf your revolution measurement is 2.5 meters, dividing that number by .5 gives you a value of 5. Rounding 5 up to the nearest even number is 6. For this example, the minimum number of magnets required is 6.

The magnets provided by Micro-Trak are marked with a punched dashed line on the SOUTH pole side of the magnet. See Illustration 3A.

Always use an even number of magnets, and always alternate the polarities of the magnets as you go around the wheel hub or drive shaft.

To install, mount the first magnet with the SOUTH pole side (dashed line) facing toward the hub or shaft. Mount the second magnet with the NORTH pole side facing toward the hub or shaft. See Illustration 3B.

For proper operation, the magnets must be evenly spaced around the wheel or drive shaft. They must have alternating polarities, and the magnets must also be at least 1” apart. See Illustration 3C.

Illustration 3A

Illustration 3B

Illustration 3C 1” Minimum

North

North

North

South

South

South1

2

4 3

5

6

Test magnetshould alternatelyattract and repel.

S

N

nOTe: Refer to appendix a for optional mounting instructions. Magnets may be attached mechanically as shown or adhered with epoxy or other high quality adhesive. When using adhesive, thoroughly clean the area of dirt and oil.

english or Turf (inches)Wheel Circumference 40 80 120 160 200Number of Magnets 2 4 6 8 10

Metric (cm)Wheel Circumference 100 200 300 400 500Number of Magnets 2 4 6 8 10

9

10

Drill lug bolthole and bend

to fit hub.Magnet

Installation (cont)

Speed Sensor Installation (cont)

attaching MagnetsThe magnets are attached to a wheel hub or drive shaft and the speed sensor is mounted directly over the magnet. When the wheel or drive shaft begins turning, a speed impulse is sent to the MT-9000 Series console every time a magnet passes by the tip of the speed sensor. For the speed sensor to operate properly, the spacing between the magnets and the tip of the sensor must always remain constant. Before permanently mounting any parts, be sure that the location you have selected will meet the following requirements. See Illustration 4.

Illustration 4

45° max

Sensor(Green body)

Magnet

3/8” nuts

Bracket mustbe rigidlymounted

Sensor assembly must notbe mounted more than 45° from perpendicular

¼” to ½” air gap

REDORGYELGRNBLUVIOGRYWHTBLK

BRN ABCDEFGHJK

10-P

IN M

ETRI

-PAC

K TO

WER

ABCDEFGHJK10

-PIN

MET

RI-P

ACK

SHRO

UD

ABC

ABC

3-PINMETRI-PACK150 TOWER

3-PINMETRI-PACK150 SHROUD

Local Access Speed Connector

MT

9000

CO

NSO

LE

BLUE TIEYELLOW TIE

Connecting the Speed Sensor Cable The speed sensor cable has a GREEN sensor body and mates with the main harness cable having a YELLOW cable tie near the 3-pin M/P connector. Make certain that you install the correct sensor cable and connect it to the correct connector on the main harness. The speed sensor and flow sensor are identical, but must be connected to the proper harness connector. The speed sensor always connects to the main harness lead with the YELLOW tie and the flow sensor always connects to the main harness lead with the GREEN tie. See Illustration 5.

InSTallaTIOn nOTe: The main harness provides two connection points for the speed sensor. for speed sensor installations in the cab or near the control console, it may be more practical to use the local access connector (yellOW tie) on the control console pigtail exiting the rear of the console. using this connection point will disable the connection point on the end of the main harness. for speed sensor installations on implements, it may be more practical to use the speed connector on the end of the main harness. When using this connection point, make certain that the local access connector for speed/distance is mated together.

SenSOR IDenTIfIcaTIOn cHaRT

SENSOR SENSOR BODY COLOR MAIN HARNESS TIE COLORSpeed Green Yellow

Flow Green Green

Run/Hold* Black Gray

*Remote run/hold is not recommended for use with NH3 systems.

Illustration 5

Installation (cont)

Connecting the Run/hold Sensor CablenOTe: Remote run/hold is nOT recommended for use with nH3 systems.

vansco Radar Speed Sensor

contact a Micro-Trak sales representative for de tails on any of these products, or call Mi cro-Trak Systems, Inc. at 1-800-328-9613.

astro II gPS Speed Sensor

Speed Sensor OptionsIn addition to the standard Hall-effect magnetic speed sensor, the MT-9000 may be interfaced with a va ri ety of other speed sensing equipment. Several options are listed below.

aSTRO SeRIeS OR OTHeR gPS SPeeD SenSOR InTeRfaceSThe MT-9000 may also be used with most GPS speed sensors that output a pulsed signal, such as the Micro-Trak Astro II and 5, SkyTrak or Dickey-John GPS speed sensors. An adapter cable may be required.

vanScO™ RaDaR SPeeD SenSORThe Vansco radar speed sensor uses a microwave (radar) signal to deliver a reliable, accurate speed signal for electronic equipment. It features state-of-the-art electronic design/manufacturing, rugged aluminum housing and complete testing and certification.

RaDaR InTeRfaceThe MT-9000 may also be interfaced with most popular radar ground speed sensors. An adapter cable is re quired for proper interface.

SEE APPENDIX H FOR LIST OF ADAPTER CABLES FOR RADAR.

gPS SPeeD SenSOR InTeRfaceThe MT-9000 may also be used with most GPS speed sensors that output a pulsed signal, such as SkyTrak or Dickey-John GPS speed sensors. An adapter cable may be required.

11

12

Installation (cont)

NH3500 Kit Installation

Illustration 7Vapor TubeHook-up

In-line Servo Valve Adapter

Flowmeter

To Manifold “Outlet” Servo Valve

Heat Exchanger

Illustration 6Remove any existing metering valves. If the old metering valve has a built-in manifold, it is recommended to install a separate new manifold for the NH3500 kit. Another option, although not recommended, is to use the existing manifold, making certain the old metering valve is in the maximum open position to allow for minimal restriction of flow through the plumbing. There also should not be any positive shut-off valves installed in the plumbing between the NH3500 kit shut-off valve and the knives.

Locate a convenient area on the applicator to install the NH3500 plumbing panel. When selecting an installation location, keep in mind that the hose from the break-away coupler must reach the strainer inlet with enough length to allow for proper operation of the disconnect mechanism of the break-away coupler and prevent kinking of the hose at hinge points. Also, the strainer’s clean-out plug should be accessible for regular cleaning. Make certain that the area selected allows for enough length of the manifold hose, between the manifold and the servo valve outlet, to prevent kinking at hinge points.

InSTallaTIOn nOTe: It is recommended to use an nH3 compatible thread sealing compound such as “Slic-tite paste with Teflon”, or a similar compound, on all pipe thread fittings. Slic-tite is manufactured by la-cO Industries, Inc./Markal company.

Remove the NH3500 plumbing panel from the shipping board. Install the plumbing panel on the tool bar frame using the carriage bolts and flange lock nuts through the top and bottom brackets of the system. Trim any excess length off of the bolts if required. Attach the hose from the break-away coupler to the strainer inlet. Check for proper hose length for operation of the disconnect mechanism of the break-away coupler. Next, connect the manifold hose to the servo valve outlet. Check for proper hose length to avoid kinking at hinge points.

nOTe: If you are working with old/dirty nurse tanks, it is recommended to install a large magnet of some sort in the strainer screen to help catch rust and scale from the nurse tank to avoid plugging the heat exchanger, flowmeter and other plumbing.

Shut-off Valve

Strainer

From Brake-A-Way Coupler Inlet

Vapor TubeHook-up

13

Installation (cont)

Equalizer Kit InstallationRemove any existing metering valves. If the old metering valve has a built-in manifold, it is recommended to install a separate new manifold for this kit. Another option, although not recommended, is to use the existing manifold, making certain the old metering valve is in the maximum open position to allow for minimal restriction of flow through the plumbing. There also should not be any positive shut-off valves installed in the plumbing between the Equalizer kit shut-off valve and the knives.

Locate a convenient area on the applicator to install the Equalizer heat exchanger and the plumbing control panel. When selecting an installation location, keep in mind that the hose from the break-away coupler must reach the strainer inlet on the Equalizer with enough length to allow for proper operation of the disconnect mechanism of the break-away coupler and prevent kinking of the hose at hinge points. Also, the strainer screen should be accessible for regular cleaning. Make certain that the area selected allows for enough length of the manifold hose, between the manifold and the servo valve outlet, to prevent kinking at hinge points.

Install the Equalizer base plate on the tool bar (using the carriage bolts and flange lock nuts) through the base plate and bottom bracket. Trim any excess length off of the bolts if required. Install the base plate adapter and Equalizer heat exchanger onto the base plate as shown in Illustration 8 on

previous page. Install the strainer screen, strainer fitting and manual shut-off valve onto the Equalizer as shown in Illustration 9. Attach the hose from the break-away coupler to the manual shut-off valve inlet. Check for proper hose length for operation of the disconnect mechanism of the break-away coupler.

Install the 1 1/4” x 18” NH3 hose to the base plate adapter outlet as shown. Remove the plumbing control panel from the shipping board. Connect the plumbing control panel to the 1 1/4” x 18” NH3 hose and secure the plumbing control panel to the tool bar frame (using the carriage bolts and flange lock nuts) through the top and bottom brackets of the plumbing panel. Install the vapor hose adapter onto the servo valve outlet. Next, connect the manifold hose to the vapor hose adapter. Check for proper hose length between the manifold and vapor hose adapter to avoid kinking at hinge points.

Locate the 3/8” x 6’ vapor hose. Install one end to the hose barb fitting on the vapor hose adapter and the other end to the hose barb fitting on the top of the Equalizer heat exchanger, as illustrated. Secure the vapor hose in place with appropriate hose clamps provided with the kit.


Vapor Tube Hook-up

FromBrake-away

Coupler

To Manifold

Inline ServoAdapter

Illustration 9

EqualizerBase Plate

1¼” x 18” NH3 HoseShut-off Valve

Flowmeter Servo Valve

StrainerScreenManual Shut-

off Valve

Equalizer HeatExchanger

3/8” x 6’Vapor Hose

Vapor HoseAdapter

Illustration 8

1¼” Strainer

1¼” Close Nipple

Raven Super Cooler

Shut-off Valve Flowmeter

Servo Valve

¼” MPT x 3/8”Hose Barb

1¼” 90° Elbow

1¼” Close Nipple1¼” x 4”NH3 Hose

3/8” x 7’Vapor Hose

InSTallaTIOn nOTe: It is recommended to use an nH3 compatible thread sealing compound such as “Slic-tite paste with Teflon”, or a similar compound, on all pipe thread fittings. Slic-tite is manufactured by la-cO Industries, Inc./Markal company.

Illustration 10

14

Installation (cont)

Raven Super Cooler Kit InstallationRemove any existing metering valves. If the old metering valve has a built-in manifold, it is recommended to install a separate new manifold for this kit. Another option, although not recommended, is to use the existing manifold, making certain the old metering valve is in the maximum open position to allow for minimal restriction of flow through the plumbing. There also should not be any positive shut-off valves installed in the plumbing between the shut-off valve and the knives.

Locate a convenient area on the applicator to install the Raven Super Cooler and the plumbing control panel. When selecting an installation location, keep in mind that the hose from the break-away coupler must reach the strainer inlet on the Super Cooler with enough length to allow for proper operation of the disconnect mechanism of the break-away coupler and prevent kinking of the hose at hinge points. Also, the strainer screen should be accessible for regular cleaning. Make certain that the area selected allows for enough length of the manifold hose, between the manifold and the servo valve outlet, to prevent kinking at hinge points.

Install the Raven Super Cooler on the tool bar following the instructions supplied from the manufacturer. Trim any excess length off of the bolts if required. Install the 1 1/4” close nipple and 1 1/4” strainer onto the Super Cooler inlet as shown in Illustration 11. Attach the hose from the break-away coupler to the manual shut-off valve inlet. Check for proper operation of the disconnect mechanism of the break-away coupler.

Install the 1 1/4” close nipple and 1 1/4” elbow on the Super Cooler outlet as shown in Illustration 11. Install the 1 1/4” NH3 hose to the 1 1/4” elbow as shown. Remove the plumbing control panel from the shipping board. Connect the plumbing control panel to the 1 1/4” x 18” NH3 hose

and secure the plumbing control panel to the tool bar frame (using the carriage bolts and flange lock nuts) through the top and bottom brackets of the plumbing panel. Install the vapor hose adapter onto the servo valve outlet. Next, connect the manifold hose to the vapor hose adapter. Check for proper hose length between the manifold and vapor hose adapter to avoid kinking at hinge points.

Install the 1/4” MPT x 3/8” hose barb fitting onto the Super Cooler inlet as shown in Illustration 12. Locate the 3/8” x 7’ vapor hose. Install one end to the hose barb fitting on the bottom of the servo valve and the other end to the hose barb fitting at the inlet of the Super Cooler, as illustrated. Secure the vapor hose in place with appropriate size hose clamps provided with the kit.


fOR all nH3 KITSWeld the steel vapor tubes to the back of your liquid tubes. All electronic equipment, including the console and Trak-Star speed sensor, MUST BE DISCONNECTED BEFORE WELDING ON EqUIPMENT. The four steel vapor tubes should be evenly spaced across the applicator (two per side) and installed so that only their wear resistant surface contacts the soil. Mount the tubes just high enough to avoid plugging.

VAPOR TUBES

WEAR RESISTANTSURFACE

GROUND LEVEL

Illustration 12

Illustration 11

Vapor Tube Hook-up

From Break-away Coupler

In-Line Servo Valve Adapter

To Manifold

15

nH3500 KIT - vaPOR lIne InSTallaTIOn

Installation (cont)

NH3500 Vapor Tube InstallationLocate the ½” EVA vapor hose supplied with the kit. Starting on one half of the tool bar, connect the ½” hose to the outside steel vapor tube. Route the hose up the shank and along the tool bar frame to the inside steel vapor tube. Allow enough extra hose to avoid kinking at hinge points. Cut the hose to length and attach to the inside steel vapor tube. Install a ½” x ¾” x ½” tee fitting approximately halfway along this hose between the outside and inside steel vapor tubes. See Illustration 13. Repeat the same procedure for the steel vapor tubes on the other half of the tool bar. Secure all hoses with properly sized hose clamps. Secure the hoses to the tool bar frame with cable ties.

Locate the ¾” EVA hose supplied with the kit. Connect to one of the ½” x ¾” x ½” tee fittings and route along the tool bar frame to other ½” x ¾” x ½” tee fitting. Cut to length and install on the tee fitting. Allow enough extra hose to avoid kinking at hinge points. Now install a ¾” x ¾” x ¾” tee fitting approximately halfway along this hose (center of the tool bar) between the other two tee fittings. Using an appropriate length ¾” hose, connect this tee fitting to the vapor tube connection on the NH3500 plumbing panel. Secure all hoses with properly sized hose clamps. Secure the hoses to the tool bar frame with cable ties.

½” Vapor Hose

BreakawayCoupler

NH3500 Kit

Steel Vapor Tubes

½” Vapor HoseManifold

½” Vapor Hose½” Vapor Hose

¾” Vapor Hose

½” X ½” X ¾” Tee

¾” Tee

½” X ¾” X ½” Tee

Steel Vapor Tubes

¾” Vapor Hose

Illustration 13

Locate the 3/4” EVA vapor hose supplied with the kit. Starting on one half of the tool bar, connect the ¾” hose to the outside steel vapor tube. Route the hose up the shank and along the tool bar frame to the inside steel vapor tube. Allow enough extra hose to avoid kinking at hinge points. Cut the hose to length and attach to the inside steel vapor tube. Install a ¾” x ¾” x ¾” tee fitting approximately halfway along this hose between the outside and inside steel vapor tubes. See Illustration 14. Repeat the same procedure for the steel vapor tubes on the other half of the tool bar. Secure all hoses with properly sized hose clamps. Secure the hoses to the tool bar frame with cable ties.

Raven Super Cooler Vapor Tube InstallationUsing the ¾” EVA hose supplied with the kit, connect to one of the tee fittings and route along the tool bar frame to the vapor hose connections on the heat exchanger. Cut to length and install on one of the vapor fittings on the heat exchanger. Using the remaining ¾” EVA hose, connect to the other tee fitting and route along the tool bar frame to the vapor hose connections on the heat exchanger. Cut to length and install on the remaining vapor fitting on the heat exchanger. Allow enough extra hose to avoid kinking at hinge points. Secure all hoses with properly sized hose clamps. Secure the hoses to the tool bar frame with cable ties.

Illustration 14 ½” Vapor Hose

BreakawayCoupler

Equalizer Kit orControl Kit for

Raven Super Cooler

½” Vapor HoseManifold

½” Vapor Hose½” Vapor Hose

¾” Vapor Hose

½” X ½” X ¾” Tee

¾” Tee

½” X ¾” X ½” Tee

¾” Vapor Hose

REDORGYELGRNBLUVIOGRYWHTBLK

BRN

TO PRESSURESENSOR

AB

AB

2-PINMETRI-PACK150 TOWER

2-PINMETRI-PACK150 SHROUD

AB

2-PINEXT. CABLE

150 SHROUD

ABCDEFGHJK 10

-PIN

MET

RI-P

ACK

SHRO

UD

MT-

9000

CO

NSO

LE ABCDEFGHJK10

-PIN

MET

RI-P

ACK

TOW

ER

WHITE(NATURAL) TIE

16

Installation (cont)

Pressure Sensor InstallationInstall the pressure sensor in an unused port of the manifold or in the hose between the heat exchanger and the manifold. Connect the 2-pin extension cable to the pressure sensor and route to the console. Locate the 2-pin local access pressure connection point on the back of the display console (console harness cable with WHITE tie) and connect extension cable to this point. (See Illustration at right).

nOTe: If the pressure sensor is nOT installed, the console display will still read “PSI 0” in the lower left display.

ElectricalThe MT-9000 Series NH3 main wiring harness is made specifically for use on anhydrous ammonia applicators. The harness combines the wires for the servo valve, flowmeter, shut-off valve and remote access speed connector into a single 10-pin connector.

Plug the main harness 10-pin connector into the 10-pin connector on the plumbing unit harness. Optional extension cables are available.

15' 10-PINM/P EXTENSION

TO PLUMBINGPANEL

BLUE TIE

RED TIE

TO CONSOLE

TO MAINPOWER CABLE

NH3 MAIN HARNESSP/N 13276

* ITEMS NOT INCLUDEDWITH SYSTEM.

SPEEDSENSOR

HOLD/CUT-OUTMODULE

HARNESS CONNECTS TONH3 PLUMBING PANEL.

LOCAL PRESSURECONNECTOR

LOCAL ACCESSSPEED CONNECTOR(IF SPEED SENSOR IS

INSTALLED ON VEHICLE).

CHASSISGROUNDPOWER

CABLE

12-VOLTPOWER

WHITEWIRE

REDWIRE

MT-9000

BATTERY*

10' 10-PINM/P EXTENSION

YELLOW TIE

17

Installation (cont)

MT-9000 NH3 System Diagram

RED TIEG

RAY TIE

CHA

SSISG

ROU

ND

(18")

BATTERYPO

SITIVE

BATTERYN

EGATIVE

REDO

RGYELG

RNBLUVIOG

RYW

HT

BLK

BRNABCDEFGHJK

10-PIN METRI-PACK TOWER

ABCDEFGHJK 10-PIN METRI-PACK SHROUD

1-PIN W

/P S A

LOCAL ACCESS RUN/HOLD CONNECTOR

RED TIE

BLUE TIE

WH

T

RED

BLK

3-PIN M/P 630SHROUD

MT-9000 CONSOLE

WH

ITE(N

ATURA

L) TIE

BLUE TIEYELLO

W TIE

1-PIN W

/P T A

ABC

ABC

3-PIN M/P 630TOWER

WH

T

RED

BLK

3-PIN M

/P 150SHROUD

3-PIN M

/P 150TOW

ER

ABC

ABC

2-PIN M

/P 150TO

WER

2-PIN M

/P 150SH

ROU

D

ABAB

REDO

RGYELG

RNBLUVIOG

RYW

HT

BLK

BRNABCDEFGHJK


REDO

RGYELG

RNBLUVIOG

RYW

HT

BLK

BRNABCDEFGHJK

ABCDEFGHJK

10-PIN METRI-PACK SHROUD


LOCAL ACCESS SPEED CONNECTORABC

3-PIN M

/P 150TOW

ER

3-PIN M

/P 150SHROUD

ABCDEFGHJK

ABCDEFGHJK

10-PIN METRI-PACK SHROUD


REDO

RGYELG

RNBLUVIOG

RYW

HT

BLK

BRN

ABC

DU

STCO

VER

BLACK TIEG

REEN TIE

GREEN

TIEH

OLD

CUT-O

UT/H

ALL-EFFEC

T AD

APTER

YELLOW

TIE

BROW

N TIE

FLOW

SERVO

DISTA

NCE

NH

3SH

UT-O

FFVA

LVE

HEAT SH

RINK

SERVOADAPTER

ABCDEFGHJK 10-PIN METRI-PACK SHROUD

WH

TBLKREDW

HT

BLKREDBLKREDBLK

REDABC

3-PIN M

/P 150TO

WER

3-PIN M

/P 150SHROUD

ABC

ABCABC

ABC

3-PIN M

/P 150TO

WER

3-PIN M

/P 150TO

WER

3-PIN M

/P 150SHROUD

ABC

ABC

ABC

ABC

3-PIN W

/P 150TO

WER

3-PINM

/P 150TO

WER

3-PIN W

/P 150SHRO

UD

3-PIN W

/P 150SHRO

UD

18

Installation (cont)

MT-9000 NH3 Wiring Diagram

19

Console FunctionsThe MT-9000 Series features a large, easy-to-read display with bold, heavy duty buttons and toggle switches, and a rugged outer case.

OPeRaTIOn POSITIOnSThe MT-9000 Series offers two different Operation positions: Speed and Flow Rate. These positions are identified by GREEN boxes with white type.

SPeeD: Displays ground speed in miles per hour (kilometers per hour).

flOW RaTe: Displays the total number of pounds (kg) of NH3 applied per minute.

calIBRaTIOn POSITIOnSThe MT-9000 Series offers six different Calibration positions: Target Rate, Adjust Rate, Boom Width, Min Flow, Flowmeter and Distance. These positions are identified by RED boxes with white type.

TaRgeT RaTe: Used to enter the target application rate in pounds of “N”/Acre (kg N/Ha).

aDjuST RaTe: Used to enter an amount of change for on-the-go adjustments to the target rate.

BOOM WIDTH: Used to enter the working width of your applicator.

MIn flOW: Used to enter the minimum flow rate.

flOWMeTeR: Used to enter flowmeter calibration value.

DISTance: Used to enter circumference value; will also display accumulated distance travelled.

cuMulaTIve TOTalS POSITIOnSThe MT-9000 Series offers four different Cumulative Totals positions: Total Area, Field Area, Total Flow and Field Flow. These positions are identified by BLUE boxes with white type.

TanK: Displays the amount of NH3 remaining in the tank.

TeST: Not for use with anhydrous ammonia application.

TOTal aRea: Keeps a running count of the total acres (hectares) worked. May be reset.

fIelD aRea: Keeps a running count of acres (hectares) worked. May be reset.

TOTal flOW: Displays total number of pounds (kg) of NH3 applied. May be reset.

fIelD flOW: Displays number of pounds (kg) of NH3 applied. May be reset.

RaTe 1, 2, 3: Displays each of three preset application rates.

ReSeT: Clears total counters when held for three seconds.

20

CalibrationGeneralIn this chapter, we will help you calibrate your system specifically for your NH3 application needs. Follow these procedures carefully to make sure you are properly prepared before you get to the field.

This system is also equipped with a Software Utility package that includes the “Calibration Wizard” program, that allows you to calibrate your system electronically. See the Compact Disc you received with your MT-9000 Series Automatic Rate Controller and the Software Utility Reference Manual.

TanKRaTe 1 RaTe 2 RaTe 3

POWeR On

Off

TeST ReSeT

auTO

Man

HOlD

auTOMaTIc RaTe cOnTROlleRMT-9000 SeRIeS

SPeeD

TOTal aRea

fIelD aRea

TaRgeT RaTe

aDjuST RaTe

BOOM WIDTH

flOW RaTe

TOTal flOW

fIelD flOW

MIn. flOW

flOWMeTeR

DISTance

PSIcal bar datameters inches

RateeRROR 1 2 3

gal / ackg / ha

lbs n / ac

liters / ha

gal / 1000

We’ll begin with the Special Calibration section. You will need to go to Special Calibration anytime your system uses a modified set-up. Modifications include: Metric or Turf measurement, Servo type other than a Micro-Trak servo valve, in-line (except NH3) versus by-pass plumbing, ball valves versus solenoid valves. If your system does not use any of these modifications, skip “Special” Calibration and go to Standard Liquid Calibration on pages 29-35.

“Special” CalibrationEntering “Special” Calibration

Illustration 15The MT-9000 Series has a number of control functions which are preset at the factory (See Factory Calibration Chart on page 29). In some cases, however, it may be necessary to change one or more of these settings to enhance performance or meet special operational requirements. To make these changes, you need to enter “Special” Calibration. To enter “Special” Calibration, do the following:

Turn the power switch OFF.1.

Place the console in the HOLD position and turn the 2. rotary dial to the SPEED position.

While holding the “+/-” switch UP, turn the power ON. 3. Release the “+/-” switch when the console has powered up.

The console will display “4. SPEC” and the warning light will flash. See Illustration 15. Dashes will appear in the lower right display until the rotary dial is moved to one of the SPECIAL CAL positions (TARGET RATE, ADJUST RATE, BOOM WIDTH, DISTANCE, FLOWMETER, MIN FLOW, FIELD FLOW OR TOTAL FLOW).

To exit 5. SPECIAL CAL mode press the RESET switch.

TaRgeT RaTePSICAL bar datameters inches

RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000 datameters inches

datameters inches

unITS Of MeaSuRe: This “Special Cal” position is used to select the units of measure for the system. The units of measure determine how data is displayed and how volume, distance and area calculations are made. Use the “+/-” switch to select the desired units of measure for the system.

EnG = American EnglishmEt = Standard metricturF = Standard Turf Units

Display will Read

Dial Position

Entering “Special” Calibration Values

aDjuST RaTe

BOOM WIDTH

PSICAL bar datameters inches

RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

21

“Special” Calibration (cont)

Entering “Special” Calibration Values (cont)

Display will ReadMaTeRIal TyPe: This “Special Cal” position is used to select the type of material that the system is controlling. The material type determines how application data is labeled on the display and how volume calculations are made. Use the “+/-” switch to select NH3 application mode for the system.

Dial PositionPSICAL bar datameters inches

RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

unITS = aMeRIcan englISH

MATERIAL RATE VOLUME AREA DISTANCE SPEED

H2O Gal/Ac Gallons Acres Feet MPH

NH3 Lbs N/Ac Lbs NH3 Acres Feet MPH

Dry Lbs/Ac Pounds Acres Feet MPH

unITS = STanDaRD MeTRIc

H2O Liters/Ha Liters Hectares Meters Km/H

NH3 Kg N/Ha Kg NH3 Hectares Meters Km/H

Dry Kg/Ha Kg Hectares Meters Km/H

unITS = STanDaRD TuRf

H2O Gal/1000 Gallons 1,000 Sq Ft Feet MPH

NH3 Lbs N/1000 Lbs NH3 1,000 Sq Ft Feet MPH

Dry Lbs/1000 Pounds 1,000 Sq Ft Feet MPH

Display will ReadSeRvO TyPe: This “Special” Cal position is used to select the correct driver for the servo valve (control valve) being installed with the system. Micro-Trak servo valves requires an 8-volt driver for optimum operation while servo valves from other manufacturers require a 12-volt driver for optimum operation. Use the “+/-” switch to select “8” for Micro-Trak servo valves or “12” for servo valves from other manufacturers.

nOTe: Do not attempt to use a “12” setting with a Micro-Trak servo valve. Damage due to over-voltage will not be covered under warranty.

Dial Position

flOWMeTeR


RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000


RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000


RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000


RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

22



Display will Read

Display will Read

Display will Read

Display will Read

SeRvO POlaRITy: This “Special” Cal position is used to designate whether the servo valve (control valve) has been

installed in a bypass line (bP) or in the main supply line going to the flowmeter and boom shut-off valves (IL). Use the “+/-” switch to select “bP” for bypass installations.

nOTe: When the system is used in conjunction with a Micro-Trak nH3 control panel, always select “BP” for the servo valve polarity.

DISTance

Dial Position

BOOM SHuT-Off valve TyPe: This “Special Cal” position is used to designate what type of boom shut-off

valve is installed in the system. Use the “+/—” switch to select “SoL” for the

type of boom shut-off valve installed.

Note: The ball valve selection is normally for use

with a 2-wire valve ONLY. If you need assistance for other wiring configurations, contact Micro-Trak for assistance.

Dial Position

BOOST valve SeTTIng: The boost valve is not for use with NH3 systems. Use the “+/-” switch to adjust the displayed value to read OFF.

MIn. flOW

Dial Position

TanK alaRM SeT POInT: This “Special Cal” position is used to set the desired tank level (lbs/Kg NH3) at which the low level alarm will activate. Use the “+/-” switch to adjust the displayed value to the desired level.

fIelD flOW

Dial Position

Display will ReadTanK SIze: This “Special Cal” position is used to set the amount of pounds (Kg) NH3 in the tank. Use the “+/-” switch

to adjust the displayed value to match the size {lbs. (Kg) NH3} of the product tank.

TOTal flOW

Dial Position PSICAL bar datameters inches

RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

23



exiting Special calibrationUpon completion of the special calibration process, exit special calibration by simply pressing the reset button. Proceed with Standard NH3 Calibration before beginning operation.

“Special” factory-loaded calibration valuesDefault values

calibration factor Purpose english Metric Turf

Tank Size Maximum Value than can be entered in “Tank” Off Off Off

Tank Set Point Alarm Activation Point Off Off Off

Units Type of Measurement English Metric Turf

Material Type Application, Flow Liquid Liquid Liquid

Servo Model Servo Voltage 8-Volt 8-Volt 8-Volt

Boost Valve Activation Percentage Off Off Off

Valve Type Shut-off Valve Solenoid Solenoid Solenoid

Servo Polarity Servo Direction Bypass Bypass Bypass


RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

24

Standard NH3 CalibrationEntering Standard Calibration

Entering Standard Calibration ValuesTaRgeT RaTe: This position is used to enter the value for the desired target application rate in units of actual “N” per acre. (For unit per area options, see Entering Special Calibration on page 26.) Up to three rates can be programmed from 0.1 to 6553.5. Press RATE 1 to enter your first rate, RATE 2 to enter your second rate, and RATE 3 to enter your third target rate. Use the “+/-” switch to adjust the value displayed to the desired rate.

Once in calibration mode, you may change any one, all or none of the values, in any order. To enter calibration mode, simply turn the rotary selector to the desired calibration position. Use the “+/-” switch to adjust values. Calibration Positions are identified as RED with white type (lower six positions).

TO enTeR calIBRaTIOnPlace the console in HOLD.1.

Turn the rotary dial to the any of the six (RED) Calibration 2. positions. The console will display CAL and the warning light will flash. See Illustration 16.

Illustration 16


POWeR On

Off

TeST ReSeT

auTO

Man

HOlD


SPeeD

TOTal aRea

fIelD aRea

TaRgeT RaTe

aDjuST RaTe

BOOM WIDTH

flOW RaTe

TOTal flOW

fIelD flOW

MIn. flOW

flOWMeTeR

DISTance


RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

Display will Read

TaRgeT RaTe

Dial Position

aDjuST RaTe


RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

aDjuST RaTe: Enter the value for the desired amount of change in units per acre to be used for making on-the-go rate adjustments when operating in AUTO. (For unit per area options, see Entering Special Calibration on page 25.) You may set an adjust rate value for each target rate. Press RATE 1 to enter the adjust rate for Rate 1, press RATE 2 to enter the adjust rate for Rate 2, and press RATE 3 to enter the adjust rate for Rate 3. Use the “+/-” switch to adjust the value displayed to the desired rate.

Dial Position

Display will Read

nOTe: If you will not be using the adjust rate feature, set the value to zero (0). This will help to prevent any accidental target rate changes.


RateERROR 1 2 3

Gal / Ackg / ha

Lbs N / Ac

liters / ha

Gal / 1000

25

Standard NH3 Calibration (cont)

Entering Standard Calibration Values (cont)

BOOM WIDTH: Enter the entire working width of the applicator, in inches (meters), for boom one. Use the “+/-” switch to adjust the displayed value to the correct width for boom one (in the top display). To advance to the next boom section, press the RESET button on the front panel. A value of “0” (.000) must be entered for all other boom sections.

BOOM WIDTH

Display will Read

Dial Position

Setting Working WidthIn order to accurately measure the number of units applied per acre (hectare), it is important to determine the correct “working” width. The working width is the width of ground being affected by any operation. This should be measured to the nearest inch (thousandth of a meter).


RateERROR 1 2 3

Gal / Ackg / ha

Lbs N / Ac

liters / ha

Gal / 1000

Display will ReadMIn flOW: The purpose of this calibration parameter is to set the minimum recommended flow rate for the flowmeter in the NH3 Kit. Once set, the system will prevent the actual flow rate from going below the

recommended minimum rating, preventing the flowmeter from stalling (turbine stopping). You may set a minimum flow rating for each target rate.

enTeRIng MInIMuM flOW valueSEach target rate has a different settings for minimum flow. Press the RATE 1 button. The lower right portion of the display will be showing the minimum flow value. Use the “+/-” switch to adjust the displayed value (lbs. NH3 per minute) to 10.0.

Repeat the procedure for RATE 2 and 3. Enter the same minimum flow values for those target rates.

MIn. flOW

Dial Position

aPPlIcaTIOn nOTe: In certain situations when applying in auTO, your ground speed may be slow enough to result in an over-application error. In other words, based on ground speed, the actual flow rate for your application is below the calibrated minimum. Remember, in auTO, the system will not allow the flow rate to drop below the calibrated minimum.


RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

26

DISTance

Display will Read


Entering Standard Calibration Values (cont)

flOWMeTeR: This position is used to enter the calibration number from the flowmeter tag. It represents the number of pulses per pound of “N” for that

particular flowmeter. The same value is used for both English and Metric. Use the “+/-” switch to enter this value.

flOWMeTeR

Dial Position

Illustration 17Your Micro-Trak flowmeter has been tested at the factory and assigned a “Flowmeter” calibration value to make it operate properly with the MT-9000 Series console. This number is stamped on the metal tag attached to the flowmeter. See Illustration 17. This is a starting point only. The value must be fine-tuned. See Fine-Tuning Flowmeter Calibration on page 34.

DISTance: This position is used to calibrate the speed sensor for accurate speed and distance measurement.

When this position is selected, the display will show the wheel circumference value and the distance travelled. Either one may be selected

to calibrate for speed and distance measurement.

nOTe: Because of the difference in wheel-to-drive shaft ratios, it is difficult to determine

a calibration value for installation on a drive shaft by measuring a wheel. you must start with an estimated calibration value and then fine-tune the calibration.

Dial PositionPSICAL bar datameters inches

RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

Display will Read

Refer to Fine-Tuning Speed/Distance Calibration for more detailed information.

Distance Traveled

Distance CAL Factor

Determining Wheel CircumferenceFor the console to calculate the correct speed and measure distance accurately, the circumference of the sensor-equipped wheel must be entered. Determine the circumference of the sensor-mounted wheel, to the nearest tenth of an inch (thousandth of a meter), with the following method:

Mark the tire with a piece of chalk and measure distance travelled on the ground for one complete revolution. See Illustration 18. For improved accuracy, it is recommended to perform this function in field conditions, measure several revolutions, and take the average.

Divide the measured revolution by the number of magnets installed to get your starting wheel circumference calibration value. Once calibration of the system is complete, this number should be fine-tuned for optimum accuracy. Please refer to Fine-Tuning Speed/Distance Calibration Value on page 33.

Illustration 18

To determine circumference, measure thedistance of one complete wheel revolution

and divide by the number of magnets installed.


POWeR On

Off

TeST ReSeT

auTO

Man

HOlD


SPeeD

TOTal aRea

fIelD aRea

TaRgeT RaTe

aDjuST RaTe

BOOM WIDTH

flOW RaTe

TOTal flOW

fIelD flOW

MIn. flOW

flOWMeTeR

DISTance


RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

27


Fine Tuning Speed/Distance Calibration ValueThis procedure is used to verify the calibration of the system. In order to achieve accurate measurements, each step in this fine tuning procedure should be performed as precisely as possible.

PRePaRaTIOn Once the system is fully installed and calibrated, select a •straight tract of ground that is similar to your actual field conditions and as level as possible.

nOTe: using a course with a different ground surface, such as a hard-surface road, will result in different readings than exact field conditions.

Measure a distance of 1000 feet (500 meters). Clearly mark •the beginning and end points with flags or something highly visible to the user.

PROceDuReWARNINg: Turn boom switches OFF to avoid product application during the following procedure.

Place the console in HOLD. The display will read HOLD. 1. Turn the rotary dial to the “DISTANCE” position. Be sure the display shows “0.” If not, reset the distance counter by pressing and holding “RESET” until the display automatically returns to 0 (approximately three seconds).

You are now ready to drive the measured course. Pick 2. a location on the vehicle to use as a marker for starting and stopping the distance counting function (e.g. door handle, mirror, step). You should begin to drive the course well ahead of the starting flag and drive past the ending flag, using the Master switch to start and stop the counting function. It is not recommended to start from a dead stop at the starting flag and stop at the ending flag.

Place the console in MAN when the marker on the vehicle 3. passes the starting flag to activate the distance counting function. The console display numbers will increase, adding to the distance total as you drive. Drive the pre-measured course and place the console in HOLD when the marker on the vehicle passes the ending flag to stop the distance counting function. Stop the vehicle in a safe and level area and continue with this procedure.

Toggle the “+/-” switch to adjust the upper display until 4. it matches the actual distance traveled.

When the number shown on the display matches 5. (as closely as possible) the actual distance driven, you have arrived at the correct calibration value. This will also fine-tune the Distance Cal factor in the lower right display.

To verify proper calibration, repeat the procedure a second time. Write down the new wheel circumference (CIRC) number (lower right display) and keep it in a safe place. If the calibration values are ever accidentally changed, you can simply re-enter this number.

28


Fine-Tuning Flowmeter Calibration

Illustration 19

This procedure is used to verify and fine-tune the flowmeter calibration. Every flowmeter is calibrated with water at the factory and stamped with a calibration value. Enter the value as a starting point and use this procedure to fine-tune that value for your specific installation and NH3 application (refer to Entering Flowmeter Calibration on page 31. This procedure should be repeated when the flowmeter installation has been altered.

PROceDuRe Start with a full nurse tank. Make certain that you have 1. an accurate scaled weight of the full tank. You will want to apply a minimum of 1,000 pounds of NH3 for this procedure. The larger the volume of NH3 used, the more accurate the calibration will be.

With the power switch ON, turn the rotary selector to the 2. FIELD FLOW position. Press and hold the RESET button until the display reads 0.0 (about three seconds).

Proceed to the field and perform actual application until 3. at least 1,000 pounds of NH3 has been applied. The larger the volume of NH3 applied, the more accurate the calibration will be. Obtain an accurate scaled weight of the total product applied.* Compare the console’s 4. FIELD FLOW reading with the known amount of NH3 that was applied. If the two amounts are within one or two percent, no fine-tuning of the flowmeter calibration is required. If the two amounts are more than two percent different, continue with the next step.

Turn the rotary selector to the 5. FLOWMETER position.

Use the “+” or “-” button to adjust the value in the 6. upper display to match the amount of NH3 applied. See Illustration 19.

nOTe: TOTal and flOWMeTeR calibration are inversely proportional (meaning, as the flOWMeTeR calibration value increases, TOTal decreases).

You will notice that the flowmeter calibration value has 7. changed. If the FIELD FLOW value is correct, write down the new flowmeter calibration value. This is your “fine tuned” value. Keep this for future reference.

Flowmeter calibration is complete. Turn the rotary 8. selector to any position other than the calibration positions (RED boxes with white type), and continue operation.

* One way to obtain a scaled weight of the total product applied is to re-weigh the tank and subtract the current weight from the previous weight. The difference will be the total amount applied.


POWeR On

Off

TeST ReSeT

auTO

Man

HOlD

AUTOM ATIC RATE CONTROLLERM T-9000 SERIES

SPeeD

TOTal aRea

fIelD aRea

TaRgeT RaTe

aDjuST RaTe

BOOM WIDTH

flOW RaTe

TOTal flOW

fIelD flOW

MIn. flOW

flOWMeTeR

DISTance


RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

29

calibration factor Purpose Default values

english Metric Turf

Target Rate 1

Application Rate 20.0 Gallons/Acre 200.0 liters/hectare 1.0 Gal/1000 Sq. Ft.Target Rate 2

Target Rate3

Adjust Rate 1 Amount of Increase orDecrease per +/- Press(During AUTO Control)

1.0 Gallons/Acre 2.0 liters/hectare 0.1 Gallons/1000 Sq. Ft.Adjust Rate 2

Adjust Rate 3

Boom 1 Width

Area andApplication Rate 120 Inches 3.048 meters 120 Inches

Boom 2 Width

Boom 3 Width

Boom 4 Width

Boom 5 Width

Boom 6 Width

Distance Speed, Distance, Area and Rate 1.75 Inches/Edge 0.044 meters/edge 1.75 Inches/Edge

Flowmeter PPG App. Rate, Flow Rate 155.0 155.0 155.0

Min Flow 1Lowest Allowable Flow Rate

in Auto 0.0 Gallons/Minute 0.0 liters/minute 0.0 Gallons/MinuteMin Flow 2

Min Flow 3

Min Pressure 1Lowest Allowable Minimum

Pressure in AUTO 0.0 psi 0.0 bar 0.0 psiMIn Pressure 2

Min Pressure 3

exITIng STanDaRD calIBRaTIOn

Upon completion of the calibration process, exit calibration by simply turning the rotary dial to any function other than the calibration functions (RED boxes with white type).

Standard Liquid Calibration (cont)

Standard Factory-Loaded Calibration Values

30

OperationConsole OperationDISPlay aReaDuring normal operation, the console will always display application rate in the upper half of the display, and will always display pressure in the lower left corner of the display (when pressure sensor is installed). The lower right corner of the display is used to show the data that corresponds with the position selected on the rotary dial (top six positions are operational positions).

For example, in the following illustration, the top half of the display tells the user that RATE 1 is selected and the application rate is 120.0 pounds of “N” per acre. The lower left portion of the display tells the user that the operating pressure is at 54 PSI. And with the rotary dial set to SPEED, the lower right portion of the display tells the user that the current ground speed is 4.5 MPH.

POWeR SWITcHThis switch controls 12-volt power to the entire system. In the OFF position, there will be no drain to the vehicle’s electrical system.

auTO/Man/HOlD SWITcHThis master switch will change the control status of the system from fully automatic control (“AUTO”), to manual control (“MAN”).

During normal operation, when the AUTO/ MAN/HOLD switch is in AUTO and the BOOM ONE switch is on, and the rotary dial is not in a calibration position, the console adjusts the servo valve to maintain the desired application rate. For example, as speed increases, the servo valve automatically opens in order to maintain the desired application rate. As speed decreases, the servo valve automatically closes to maintain the application rate.

During normal operation, when the AUTO/ MAN/HOLD switch is in MAN and the BOOM ONE switch is on, the application rate will not be maintained by the console automatically. For example, the MAN position may be used by the user to do things such as spot applications.

Using the “+/-” switch while in MAN allows the user to control the increase or decrease of flow or pressure as needed.

During normal operation, when the BOOM ONE switch is OFF, the console will turn the applicator off, application will stop and acre, gallon and distance counters will stop. For example, when turning on end rows, place the BOOM ONE switch to the OFF position. This disables area and distance counters.

“+/-” SWITcHThe “+/-” switch serves many functions within the system, and can be used within Calibration and Operation (AuTO and MAN).

During normal operation, when automatic (AUTO) control mode is active, BOOM ONE is on, and the rotary dial is not in a calibration position, each toggle of the switch will increase or decrease the target application rate by the amount of the calibrated adjust rate (“Delta”).

During normal operation, when manual (MAN) control mode is active, BOOM ONE is on, and the rotary dial is not in a calibration position, toggling the ”+/—” switch will increase or decrease the application rate by closing or opening the servo valve (control valve).

BOOM SWITcHeSThe BOOM ONE switch on the console is used to start and stop the flow of material through the NH3 kit, installed on the tool bar. The console accumulates area based on the calibrated applicator width (Total width of applicator should be set in calibration for BOOM ONE). See Calibration, page 30. When the BOOM ONE switch is turned on, the boom shut-off valve should be on. When the BOOM ONE switch is turned off, the boom shut-off valve should be off. Additionally, the shut-off valve should not be on if the console’s Master Switch is in HOLD, or in AUTO while speed is zero.


POWeR On

Off

TeST ReSeT

auTO

Man

HOlD

AUTOM ATIC RATE CONTROLLERM T-9000 SERIES

SPeeD

TOTal aRea

fIelD aRea

TaRgeT RaTe

aDjuST RaTe

BOOM WIDTH

flOW RaTe

TOTal flOW

fIelD flOW

MIn. flOW

flOWMeTeR

DISTance


RATEERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

31

RaTe BuTTOnSThe Rate buttons serve many functions within the system, and can be used within Calibration and Operation (AUTO and MAN). The rate buttons allow you to quickly select an alternative pre-programmed rate. They can be used in several different ways.

While in calibration, the Rate buttons are used to set three separate target rates. To do this, turn the rotary knob to the TARGET RATE position, press the appropriate rate button, and use the “+/-” keys to enter and adjust to the desired value.

While in operation, the Rate buttons are used to select which pre-programmed rate you will use during application. For example, RATE 1 could be set at a low-end rate (e.g. 50 lbs. “N”/acre), Rate 2 at a mid-range rate (TARGET, e.g. 100 lbs. “N”/acre), and Rate 3 a high-end rate (e.g. 150 lbs. “N”/acre).

TanK BuTTOnThis button is used during normal operation to check the pounds of NH3 (Kg/NH3) remaining in the tank. With the rotary dial in any of the six operational positions (BLUE and GREEN), pressing and holding this button will enable the upper half of the display to readout the pounds (Kg/NH3) remaining in the tank. By releasing the TANK button, the display will revert back to the application rate.

TeST BuTTOnThis button is used to enter the Test Speed mode when calibrating the system. This button is nOT for use with anhydrous ammonia application.

ReSeT BuTTOnDuring normal operation, this button is used to reset a counters register to zero. Refer to resetting counters for more information. In standard calibration mode, this button is used to select boom sections for calibration. In special calibration mode, pressing the reset button will exit this mode. Refer to calibration for more information.

Operation (cont)

Console Operation (cont)

ROTaRy DIalDuring normal operation, you can view any one of six monitored functions in the lower right portion of the display (data window) by turning the rotary dial to the appropriate position. The GREEN and BLUE positions are Operational positions and the RED positions are Calibration positions. See Illustration to the right.

SPeeD Displays the ground speed in miles (kilometers) per hour.

flOW RaTeDisplays the actual units of NH3 per minute being applied.

TOTal aRea Displays the area covered since the counter was last reset to zero. This counter does not accumulate area when the console is in HOLD or if all boom switches are turned off. This counter may be reset to zero independent of other system counters.

fIelD aRea Displays the area covered since the counter was last reset to zero. This counter does not accumulate area when the console is in HOLD or if all boom switches are turned off. This counter may be reset to zero independent of other system counters.

TOTal flOW Displays the total units of NH3 applied since the counter was last reset to zero. This counter may be reset to zero independent of other system counters.

fIelD flOW Displays the total units of NH3 applied since the counter was last reset to zero. This counter may be reset to zero independent of other system counters.

WaRnIng DevIceThe console is equipped with a RED warning light. The light will automatically turn on and flash when the actual application is plus or minus 10 percent from the calibrated target rate. If this light stays on while in AUTO, refer to the troubleshooting section of this manual. The RED warning light will also be illuminated when calibration mode is active on the console.

lIgHT SenSORThe small round window near the upper left corner of the display is a light sensor. This sensor automatically turns the back lighting for the front panel on or off as the lighting conditions dictate.

nOTe: The contrast of the display and the intensity of the backlighting cannot be adjusted.

vaRIaBle RaTe TecHnOlOgyVariable Rate Technology, or VRT, allows you to connect the console to the computer, giving the computer the ability to operate the system based on information collected during harvest, soil sampling, etc.


POWeR On

Off

TeST ReSeT

auTO

Man

HOlD


SPeeD

TOTal aRea

fIelD aRea

TaRgeT RaTe

aDjuST RaTe

BOOM WIDTH

flOW RaTe

TOTal flOW

fIelD flOW

MIn. flOW

flOWMeTeR

DISTance


RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

32

Operation (cont)

Resetting System Counters

Illustration 20The TOTAL AREA, FIELD AREA, TOTAL FLOW, FIELD FLOW, FLOWMETER and DISTANCE counters maintain a running count during operation regardless of the position of the rotary dial. When any of these counters reach their maximum capacity, or when you want to start a new count, the value in the register may be reset to zero by performing the following routine. Counters may be reset independently of each other.

Place the console in HOLD.1.

Turn the rotary dial to the counter position you wish to 2. reset.

Press and hold the 3. RESET button until the display reads zero.

Release the 4. RESET button and resume normal operation. See Illustration 20.

nOTe: fIelD flOW and flOWMeTeR are cleared together.


POWeR On

Off

TeST ReSeT

auTO

Man

HOlD


SPeeD

TOTal aRea

fIelD aRea

TaRgeT RaTe

aDjuST RaTe

BOOM WIDTH

flOW RaTe

TOTal flOW

fIelD flOW

MIn. flOW

flOWMeTeR

DISTance


RateERROR 1 2 3

gal / Ackg / ha

Lbs N / Ac

liters / ha

gal / 1000

Field OperationAlways follow accepted safety precautions. Make sure that equipment is in good operating order. Before connecting the tank to the applicator, check the electric shut-off valve for proper operation.

After changing tanks or after other periods of long shut- down, operate the system in MAN until the application rate stabilizes. This allows the heat exchanger to reach operating temperature before selecting AUTO. Erratic operation may be experienced if AUTO is selected before operating temperature is reached.

Manifold pressure is very important for good distribution of NH3. Use barbed fittings with properly sized orifices or an adjustable manifold to maintain adequate pressure. If manifold back pressure is too low, proper cooling will not be achieved, vapor bubbles will be allowed to enter flowmeter, and readings will be inaccurate. Typical manifold pressure ranges from 15 to 60 PSI/1 to 4.1 bar depending on application rates and ambient temperature. If manifold pressure stops climbing but FLOW RATE continues to climb, vapor bubbles are present.

In hilly or rough conditions the nurse tank dip tube will not remain submerged, allowing extra vapor in the system. This vapor is too much for the heat exchanger to condense and the system will exhibit erratic operation. If the dip tube remains out of liquid, operation may appear to be normal, but the system is simply metering vapor. If this occurs, you will notice extremely low manifold pressure. Change tanks before the NH3 level is low enough to cause these problems.

In NH3 control systems, location of the frost build-up is an indication of system performance. The MT-9000 Series system will normally have frost on the output side of the servo valve and in some cases, a small amount on the bottom portion of the heat exchanger. Frost before the servo valve indicates excessive pressure drop in the delivery system or restricted vapor lines.

The strainer is a common source of excessive pressure drop and should be cleaned regularly. afTeR cOMPleTely BleeDIng THe SySTeM, remove the large plug and carefully clean the strainer’s screen. Also, periodically check the vapor tubes for obstructions.

33

TroubleshootingGeneralAll MT-9000 Series consoles, flowmeters and servo valves are tested prior to packaging, so unless there has been damage in shipment, everything will be operational when you receive it.

However, if you do encounter a problem that appears to be related to equipment failure, PleaSe DO nOT OPen THe cOnSOle. Your system is protected by a warranty, and Micro-Trak will gladly correct any defect.

Many problems are the result of mistakes in installation or operation. Before returning any parts for service, carefully check your installation and review the operating instructions. For easy-to-follow guidelines, refer to the troubleshooting section which follows.

cOnSOle aPPeaRS DeaDUsing your MT-101 or homemade test light, check for 12 volts at the power source. Also check for damaged power cable or reversed terminals. (Console requires 12 volts for proper operation). Check for blown fuses.

SPeeD IS alWayS zeRO OR eRRaTIcCheck for properly calibrated wheel circumference.

Review speed sensor installation. Check for proper mounting, alignment and spacing of speed sensor in relationship to magnets. Make sure magnet polarities are alternated. Also check cable for breaks or incomplete connection.

For more suggestions/solutions to speed problems, see Hall-effect inputs and console inputs on pages 43-44.

aRea cOunT IS InaccuRaTeImplement width or wheel circumference was measured incorrectly or programmed incorrectly. Go back through the original procedures, make changes, and test for acre (hectare) count again. Verify accuracy with this formula:

acres = Distance x Width (in feet) / 43560

DISTance cOunT IS InaccuRaTeWheel circumference was incorrectly measured or entered. Review calibration, readjust and test.

nO ReaDOuT Of POunDS, OR POunDS PeR MInuTeCheck to see that all valves and related equipment are operating properly. If material is flowing through the line, check the flow sensor to be sure it is screwed all the way into the flowmeter.

Check to see that a FLOW CAL number has been entered. Also check cables for breaks or incomplete connections.

If the flowmeter is new or has not been used for a long period of time, the turbine may be sticky. Flushing the system out with water should make the turbine spin freely.

Flow rate may be too low to register a reading, or foreign material may be lodged in the flowmeter.

TOTal nH3 uSeD IS InaccuRaTenOTe: aPP RaTe refers to “n” (units of nitrogen). flOW RaTe, TOTal and fIelD flOW refer to nH3 (total product).

This may result from an incorrectly entered FLOW CAL value. Check the number stamped on the flowmeter tag, and be sure this is entered in the console’s Flowmeter position. If the meter has been used frequently, wear may have changed the FLOW CAL value. See Fine-Tuning Flowmeter Calibration on page 32.

Check to see that the flow sensor is screwed all the way into the flowmeter.

Other causes may be a flow rate that is too low to register, or foreign material lodged in the flowmeter.

6553.5 MeSSage DISPlayeD In RaTe MODeIf this number appears when your equipment is standing still, it indicates that the boom valve is open or not completely closed and liquid is passing through the system.

nOTe: 6553.5 may also temporarily appear when valves are closed if liquid is sloshing back and forth through the flowmeter, or if a portion of the line drains out. In this case, no corrective action is required.

If this message appears when you are in motion with the NH3 kit on, it indicates that speed sensor impulses have been lost.

cOnSOle IS eRRaTIc In OPeRaTIOnIf you have a two-way radio, it may be mounted too close to the console. Keep all MT-9000 Series cables away from the radio, its antenna and power cable.

Ignition wires may be causing the console to malfunction.

Keep MT-9000 Series cables away from ignition wires, or install ignition suppressor.

Reroute all cables away from electric solenoids, air conditioning clutches and similar equipment.

DISPlayeD MeaSuReMenTS DO nOT MaKe SenSeThe console may be in the incorrect measurement mode (English, Metric or Turf Units). See page 23 for details.

DISPlay ReaDS “Ofl”DISTANCE, TOTAL AREA, SUB AREA, FIELD FLOW and TOTAL FLOW will read “OFL” when they have exceeded their maximum count. Reset to zero to resume counting.

34

Troubleshooting (cont)

Checking Individual ComponentscOnSOleThe only way to field test a console is to connect it to a harness on a vehicle with a known working console or install it on an E-POP (Electronic Point-of-Purchase) display stand.

HaRneSSThe harness can be checked using an ohmmeter or the MT-101 (continuity tester). The main wiring diagram shows the pin-out of all connectors. See page 19.

elecTRIcal InTeRfeRenceErratic operation of the system may be the result of electrical interference from ignition wires or inductive loads (electrical clutch, fan, solenoid, etc). Always try to route wires as far away from suspect areas as possible. If problems occur, you may need to relocate the console and/or wiring harness, or install a noise suppressor and/or spark plugs.

POWeRThe power cable has a three-pin connector labeled A, B, and C. Check between A-C with a volt meter or test light. If there is no power, trace cable toward battery looking for breaks. Also check any fuses or circuit breakers that supply power to the console.

acceSSORy POWeRThe speed, flow and run/hold cables all have an accessory power wire. Check for 12 volts between B (usually white) and C (usually black) of these connectors. If power is not present, make sure the accessory power wire is not open or shorted to ground or to another wire. If this wire has a problem, the console may exhibit erratic behavior or not function at all.

MagneTIc Hall-effecT SPeeD anD flOW SenSORScauTIOn: Improper connection or voltage could damage the Hall-effect sensor.

The Hall-effect sensor works similar to a reed switch, but requires power in order to function. Also, this particular type of Hall-effect sensor requires alternating magnetic polarities in order to switch. This means that the north pole of a magnet will “open” the Hall-effect and the south pole of a magnet will “close” the Hall-effect. The Hall-effect will remain “latched” without the presence of a magnet.

Ground pin C (black) and connect clean 12 volts to pin B (white) of the Hall-effect sensor cable. Connect the positive lead (red) of an ohmmeter or continuity tester to pin A (red) and the negative lead (black) of the ohmmeter or continuity tester to pin C (black) of the Hall-effect sensor cable.

Holding the tip of the sensor to the north pole of a magnet should result in a very high resistance (infinite), while holding the sensor up to the south pole of a magnet should result in a very low resistance (near zero).

TRaK-STaR ulTRaSOnIc SPeeD SenSORMake certain that the Trak-Star is emitting a “crackling” sound. If not, check for power at pins A (white) and B (blue) of the adapter cable’s 6-pin connector. Also make certain that the BLUE wire is securely connected to chassis (frame) ground. Check connection for good metal-to-metal contact.

If the ground surface that you are traveling over is too smooth (some blacktop and concrete surfaces, especially wet, icy or snow covered), the speed reading may go to zero, be erratic or be slow to respond. If the Trak-Star is making a “crackling” sound and the ground doesn’t appear to be too smooth, try mounting the Trak-Star pointing forward and as far to the front of the vehicle as possible. (Echo interference problem: See Trak-Star Installation and Operator’s Manual for details.)

35

Troubleshooting (cont) Checking Individual Components (cont)

cOnSOle InPuTSIf there is no response from any of the following tests, refer to the main wiring diagram on the page 18 to locate the next connector in line toward the console and repeat the test at that connector. If there is a response at that connector, the problem may be in the cable between the two connectors (or the connectors themselves).

SPeeD InPuT: Turn the rotary dial to the speed position and disconnect the speed sensor (yellow tie) from the main harness. Check for 12 volts between pins B (white) and C (black) of the main harness speed cable (yellow tie). Using a clip lead or other jumper wire (such as a paper clip bent in a “U”), rapidly short together pins A (red) and C (black) of the 3-pin connector several times (See Illustration 21). The console should respond with some speed reading. If not, harness may be defective. Check for cut or pinched wires. Make sure that the local access is connected.

flOW InPuT: Turn the rotary dial to the flow rate position and disconnect the flow sensor (green tie) from the main harness. Check for 12 volts between pins B (white) and C (black) of the main harness flow cable (green tie). Using a clip lead or other jumper wire (such as a paper clip bent in a “U”), rapidly short together pins A (red) and C (black) of the 3-pin connector several times (See Illustration 21). The console should respond with some flow rate reading. If not, harness may be defective. Check for cut or pinched wires. Make sure that the local access is connected.

PReSSuRe SenSOR InPuT: The only way to field test the pressure sensor input is to connect it to a known working pressure sensor, apply pressure and verify the correct pressure reading on the console display.

flOWMeTeRShaking the flowmeter end to end should produce a “rattling” sound (shaft end play). Blowing in the meter from either end should spin the turbine freely. If the turbine spins freely but the meter will not register flow with a known working sensor, the turbine may be defective. See Flowmeter Assembly and Cleaning on page 41 for details.

SOlenOID valveSIf 12 volts are present between the two harness wires to solenoid, but valves will not activate, consult the solenoid valve manufacturer.

Ball valveSIf the voltage reverses when switch is thrown, but valve does not run, valve may be defective. Consult your valve manufacturer.

SeRvO valve cOnTROl SIgnalThe servo valve control signal cannot be checked without a load. Connect a known working servo valve or other suitable load (12-volt test light or 100-ohm resistor).

Turn console power switch to ON, place the console in “MAN” mode and turn the boom one switch ON. Using a volt meter, check from a good frame ground to each servo wire (red and black on 3-pin, violet and gray on 10-pin). There should be about six volts on each wire. Holding the “+/-” switch up (“+”) should cause one wire (black or gray) to pulse from six toward four volts and the other wire (red or violet) to pulse from six toward eight volts. Holding the “+/-” switch down (“-”) should cause the opposite results.

SeRvO valveThe best way to test the servo valve is with a known working console. Flip the power switch to ON, place the console in “MAN” and turn all the boom switches ON. With the servo valve connected to the servo valve lead on the main harness, holding the “+/-” switch up (“+”) should open the servo valve. Holding the “+/-” switch down (“-”) should close the servo valve (provided the console has passed the Servo Valve Control Signal Test). The servo valve should operate smoothly from fully open to fully closed, in both directions. If a known working servo valve will not run at all or takes more than 20 seconds to run from fully open to fully closed, check for low voltage or poor power connection.

You may also use a 9-volt transistor battery. Connecting the battery to each terminal on the servo valve should cause it to run in one direction. Reversing the battery connections should cause the servo valve to run the other direction. The servo valve should operate smoothly from fully open to fully closed, in both directions. DO nOT connect 12 volts directly to the servo valve. Damage may result.

PReSSuRe SenSORThe only way to field test the pressure sensor is to connect it to a known working console, apply pressure and verify the correct pressure reading on the console display.

C B A

Illustration 21

-------- WaRnIng --------To prevent serious injury, do the following:

1. Always wear gloves, goggles and other necessary equipment when handling NH3 apparatus.

2. Do not cross thread. Use anti-seize lead base thread compound.

3. Thoroughly bleed hoses before disconnecting NH3 apparatus.

4. Completely evacuate NH3 apparatus before servicing.


Plumbing Panel HarnessThe MT-9000 Series NH3 plumbing panel harness is installed on the plumbing panel at the factory. It connects the flowmeter, servo, shut-off valve and remote access speed to the main harness. This harness also contains the hold/cut-out Hall-effect adapter, which disables flow pulses from reaching the console when the shut-off valve is off.

A B C

A B C

YELLOW TIE

GREEN TIE

HOLD/CUT-OUTHALL-EFFECT ADAPTER

HARNESS CONNECTS TONH3 PLUMBING PANEL.

IN-LINESERVO ADAPTER

FLOW SENSOR

SHUT-OFF VALVE

MAIN HARNESSCONNECTION

REMOTE ACCESS SPEEDCONNECTOR (IF SPEED SENSOR

IS INSTALLED ON TOOL BAR).

nH3 PluMBIng PanelMaIn HaRneSS

P/n 13273

nOTe: Remote run/hold IS nOT recommended for use with nH3 systems.

36

37


Flowmeter Cleaning and AssemblyIMPORTanT: Opening the flowmeter will void the flow calibration value assigned to your unit. However, you may need to take the flowmeter apart for periodic cleaning or to remove an obstruction.

If you can shake the flowmeter from end-to-end to produce a “rattling” sound (shaft-end play), or if you can blow into the meter from either end and cause the turbine to spin freely, your flowmeter does not need cleaning. If you cannot hear the “rattling” sound or get the turbine to spin freely, your flowmeter needs to be cleaned. See Illustration 22B below for reassembly instructions.

OPenIng flOWMeTeRCut the calibration tag retaining wire. Remove the screws and disassemble the flowmeter. Do not attempt to remove the sleeve bearings from the flowmeter housing.

Use warm water and if necessary, a mild detergent and a soft bristle brush to clean all parts. DO nOT uSe SOlvenTS OR DIeSel fuel TO clean THe flOWMeTeR. A magnet works well for removing fine metallic particles from the turbine.

Inspect all parts. Check for excessive bearing or shaft wear. The shaft will wear shorter until the turbine drags on the housing. Illustration 22A shows you what a new shaft looks like. When both ends of the shaft are worn to the point of drag, the turbine must be replaced.

nOTe: The turbines have magnets built into the fins. There are no visible magnets on the inside of the cavity.

On a flat surface, place each housing half on end. Set and spin the turbine in each half. It should spin freely. If it does not spin freely, remove the turbine, wipe the shaft and try again. If is still does not spin freely, the shaft or bearings may have excessive wear. (Service may be necessary).

aSSeMBlIng flOWMeTeRPlace turbine in non-sensor housing. Position Teflon gasket on housing. (Teflon gasket may be reused, but will eventually need to be replaced). Carefully set other housing in place. Drop all screws into holes. Hold nuts in place and finger-tighten screws. Making sure Teflon gasket is still properly aligned, evenly tighten all screws. Attach tag.

After assembly, shaking flowmeter end-to-end should produce a “rattling” sound (shaft-end play). Blowing into the meter from either end should cause the turbine to spin freely. If the turbine only spins from one direction, install the flowmeter so that the liquid flows in that direction.

Accuracy of flowmeter readings cannot be guaranteed for flow rates below the meters’ ‘minimum pounds per minute’ rating. Recalibration is required before field operation.

New Shaft

Housing FM 750 N with SensorReceptacle, Including Bearing

P/N 10145

Housing, Includes BearingP/N 10116

TurbineP/N 14836

Gasket PinP/N 10137

Illustration 22B

Illustration 22A

38

Appendices

39

Appendix AOptional Speed Sensor Installation

Speed Sensorand Bracket

¼” Bolts,Lockwashersand Nuts

Speed Sensor

Cable Tie

Implement WheelsPrepare and install magnet clips as shown.1.

Place a magnet at the end of each clip (longest side of 2. magnet should point in the direction of wheel rotation).

Rigidly mount sensor mounting bracket to the wheel 3. assembly. Cut or bend “L” bracket as required for proper positioning of sensor.

Install sensor, adjust to correct spacing (1/4” to 1/2” 4. or 6 to 13 mm is recommended), and secure with 3/8” locking nuts.

front Tractor Wheel

When possible, attach magnet clips as shown for imple-1. ment wheel. This may require substituting longer lug bolts and securing clips with nuts. Magnet clips may also be secured by drilling and tapping holes for smaller bolts directly into the hub, or with an adhesive.

Mount the speed sensor bracket to a part of the wheel 2. assembly that does not change position to the hub when the wheels are turned. If the “L” bracket provided cannot be bent and mounted to properly position the sensor, make a bracket similar to the one shown at right.

Insert sensor, adjust spacing and secure with 3/8” locking 3. nuts.

FABRICATED BRACKET

Sensor

3/8” nut

Optional sectionof hose to

protect cable

3/8” nut

3/8” holefor sensor

Hub

Top View

Cable Tie

Speed Sensor

Tap thread forbolts or weld

aTv WheelsTwo mounting examples are illustrated.

Using one cable tie (ribbed side toward 1. magnet), secure two magnets to the wheel hub so they are exactly opposite each other. Alternate the magnets’ polarities.

Cut and bend sensor mounting bracket as 2. needed and rigidly mount. See Illustration, top right.

Insert sensor, adjust spacing (1/4” to 1/2” or 3. 6 to 13 mm) and secure with 3/8” locking nuts.

cauTIOn: Make sure valve stem cannot make contact with sensor or bracket.

Sensor Bracket

Axle

Nut

Swing ArmHub

Rim

PlasticCable

Tie

Magnet

Cut Bracketto Clear Rim

Cut and BendBracket asRequired

MetalHose

Clamps

ForkTube

Axel

Hub

Rim

Magnet

40

Appendix A (cont)

Optional Speed Sensor Mounting on Drive ShaftnOTe: This is an optional method generally used on pickups or custom vehicles. It may also be nec es sary on any other vehicles where ac cess to the wheels is lim it ed. This in stal la tion requires a spe cial calibration procedure. See pages 27-30.

Determine the best location for the magnets on drive shaft according to which is the most practical spot to attach sensor mounting bracket. This position should be no more than 12” (.30 meters) behind the front U-joint. For best results, mount “L” bracket to transmission and mount magnets on drive shaft as close to transmission as pos si ble. This will en sure prop er alignment if drive train shifts under heavy loading.

Two magnets are required for proper Hall-effect speed sensor operation. Position them exactly opposite each other (180 de grees apart). The polarity (north and south poles) detect ed by the Hall-effect speed sen sor must alternate as the shaft is turned. The magnets provided by Micro-Trak are marked with a punched dashed line on the SOUTH pole side of the magnet.

Attach magnets onto drive shaft, one NORTH pole side •out and the other SOUTH (dashed) pole side out, by wrapping ca ble tie around shaft and magnets. Position

each mag net so that its longest dimension moves in the di rec tion of rotation. Pull cable tie tight and trim off excess. An adjust able, non-magnetic (stain less steel) band clamp may also be substituted.

Attach sensor bracket to vehicle transmission •with bolts, lockwashers and nuts provided. See Illustration below. (Use self-tapping screws if bolts are not prac ti-cal.) Use either the short or long end of the brack et as a base. (Allow enough room be tween the bracket and the magnets so that when prop erly spaced, the tip of the sensor will extend 1/4” [7mm] or more be yond the lock ing nut.)

Turn one locking nut onto threaded sensor and in sert •sensor into large hole selected on mount ing brack et. Turn on remaining locking nut. Set sensor to proper distance from magnets (1/4” to 1/2”, or 6 to 13mm). When distance is set, tight en nuts to lock sensor in place.

Secure sensor cable to frame with cable ties. Place first •tie as close to sensor assembly as possible.

nOTe: If you are using more than two magnets, please follow the directions on page 9.

Transmission/ Transfer Case Drive Shaft

Magnets Positioned180° Apart

¼” to ½” (6mm to 13mm)

Spacing

Sensor Body(Green)

Fasten Sensor Bracket withExisting Transmission Bolts

or Rigidly Attach with Clamps.

Appendix BConversion Chart

English to MetricWhen You Know Multiple By To Find

LINEAR MEASUREMENT

inches 25.4 millimeters

feet 0.305 meters

yards 0.914 meters

miles 1.61 kilometers

LAND MEASUREMENT

square inches 645.16 square millimeters

square feet 0.093 square meters

square yards 0.836 square meters

acres .405 hectares

square miles 2.59 square kilometers

LIQUID MEASUREMENT

fl uid ounces 29.57 milliliters

pint 0.473 liters

quart 0.946 liters

gallons 3.785 liters

VOLUME

cubic feet 0.028 cubic meters

cubic yards 0.765 cubic meters

DRY MEASUREMENT

quart 1.101 liters

peck 8.810 liters

bushel 35.239 liters

FUEL CONSUMPTION

10 miles per gallon = 4.25 kilometers per liter

Metric to EnglishWhen You Know Multiple By To Find

LINEAR MEASUREMENT

millimeters .039 inches

meters 3.28 feet

meters 1.09 yards

kilometers .62 miles

LAND MEASUREMENT

square millimeters 0.00155 square inches

square meters 10.764 square feet

square meters 1.195 square yards

hectares 2.47 acres

square kilometers 0.386 square miles

LIQUID MEASUREMENT

milliliters 0.034 fl uid ounces

liters 0.529 pint

liters 0.264 quart

liters 2.64 gallons

VOLUME

cubic meters 35.314 cubic feet

cubic meters 1.307 cubic yards

DRY MEASUREMENT

liters 1.101 quart

liters 8.810 peck

liters 35.239 bushels

FUEL CONSUMPTION

10 kilometers per liter = 23.5 miles per gallon

Symbols Symbols Symbols

in. = inches pt. = pint km = kilometers

ft. = feet qt. = quart mm2 = square millimeters

yd. = yards gal. = gallon m2 = square meters

ml. = miles ft3 = cubic feet ha = hectares

in2 = square inches yd3 = cubic yards km2 square kilometers

ft2 = square feet pk. = peck ml = milliliters

yd2 = square yards bu. = bushel l = liters

ml2 = square miles mm = milliliters dal = dekaliters (10 liters)

fl oz. = fl uid ounces m = meters m3 = cubic meters

Conversion Abbreviations

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42

Appendix CReplacement Parts ListThe following replacement parts are available from your dealer or distributor, or directly from:

Micro-Trak Systems, Inc.P.O. Box 99, 111 east leRay avenue

eagle lake, Mn 56024-0099When ordering parts, please list the model number of your console and the description and part number of each part that you want to order.

PaRT nuMBeR DeScRIPTIOn

10423 Console Mount Knob 10470 Console Mount Washer 13254 Console Mount Kit 13096 5’ Flow Sensor Cable 01545 Power Cable Kit 13083 5’ Flow, Run/hold, Servo, Boom 1 Harness 13084 5’ Pressure, Boom 2, 3 & 6, Boost Harness 13085 5’ Return Flow, Distance, Boom 4 & 5 Harness 13255 Reference Manual 13256 Pressure Sensor with 3’ Cable 10013 Speed Sensor Mount Bracket 10080 Magnet Clip 12069 Magnet Kit (6 Magnets per Kit) 13096 Speed Sensor Cable 01531 Wheel Speed Sensor Kit 01533 Drive Shaft Speed Sensor Kit 01535 Run/hold Sensor Kit 13226 5’ Run/hold Sensor Cable 13276 NH3 Main Harness

OPTIOnal 2-PIn, 3-PIn, anD 10-PIn MeTRI-PacK 150 exTenSIOn caBleS:

Part No. M/P 2-Pin Part No. M/P 3-Pin Part No. W/P 3-Pin Part No. M/P 10-Pin

13200 5-foot 13205 5-foot 10450 5-foot 13220 5-foot





43

Appendix DGlossary of TermsaPPlIcaTIOn RaTe: An amount, unit or ratio of material being applied.

aSTRO SeRIeS Of gPS BaSeD SPeeD SenSORS: A direct replacement for magnetic wheel speed sensors or radar guns and can interface to most brands of monitors and controllers.

BOOM: The entire apparatus which holds the nozzles of a sprayer.

BOOM SecTIOn: The portion of the boom which is supplied by a shut-off valve.

BOOST aDjuST valve: A device that determines the amount of by-pass the boost valve will provide; typically the amount of material that was flowing through the boom sections that were shut-off to cause boost activation.

ByPaSS InSTallaTIOn: An installation in which the servo valve is installed between the high and low pressure sides of the system (pump outlet/pump inlet), therefore allowing more bypass as the servo opens. [Open servo = more bypass = lower pressure = less output; closed servo = less bypass = higher pressure = more output.]

cOnSOle: The main instrument panel, containing programmed software, used to operate the MT-9000 system.

cOnTROl MODe: A mode which determines the information used to adjust the systems output. Choices include flow, pressure or hybrid (flow and pressure combined).

DRIve SHafT: A shaft that transfers power from one place to another.

flOW-BaSeD cOnTROl: Using information from a flowmeter to determine the amount of adjustment required.

flOWMeTeR: The device that measures flow through the system.

flOW SenSOR: An electronic device that sends a signal to the console to calculate and display flow-related functions.

HyBRID-BaSeD cOnTROl: Using information from a flowmeter and a pressure sensor to determine the amount of adjustment required.

InlIne InSTallaTIOn: An installation in which the servo valve is installed in the high pressure side of the system (between pump and boom).

nOn-DRIven WHeel: A wheel that is free-rolling on the ground, as opposed to the wheel being driven by or driving other devices.

OuTPuT: The amount of material applied.

PReSSuRe-BaSeD cOnTROl: Using information from a pressure sensor to determine the amount of adjustment required.

PReSSuRe SenSOR: An electronic device typically mounted between the pump output and the boom shut-off valves (near the flowmeter) that sends a signal to the console to calculate and display pressure.

Range aDjuST valve: A valve installed between the high and low pressure sides of the system (pump outlet/pump inlet) to provide extra bypass when the pump is much larger than required.

RelIef valve: A valve installed between high and low pressures sides of the system that opens to avoid excessive pressure build-up and possible damage when all boom sections are shut off.

SeRvO valve: A device which adjusts the amount of product being applied.

SHROuD: The female plastic portion of the connector typically containing male electrical contact pins.

SPecIal calIBRaTIOn: A calibration mode sequence that provides access to an extended list of calibration parameters.

SPeeD SenSOR: An electronic device that sends a signal to the console to calculate and display speed-related functions including distance and area.

STanDaRD calIBRaTIOn: A calibration mode of the MT-9000 Series which lets the operator enter values specific to their operating needs.

TaRgeT RaTe: The desired amount of material which is to be applied.

TOWeR: The male plastic portion of the connector typically containing female electrical contact pins.

vanScO: A device using microwave to deliver a reliable speed signal for electronic equipment.

unITS: A standard quantity with which others of the same kind are compared for purposes of measurement. For example, Units of Area = Acres (English), Hectares (Metric) and/or Thousand Square Feet (Turf).

ManufacTuReD In THe u.S.a. By

111 East LeRay Avenue • P.O. Box 99 • Eagle Lake, MN 56024-0099

Toll free: (800) 328-9613 • (507) 257-3600fax: (507) 257-3001

www.micro-trak.com • [email protected]

© 1999 Micro-Trak Systems, Inc. •Printed in U.S.A. •P/N 13797 Rev. 1

mt-9000 tm - micro-trak

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