System Requirements Performance Features Compatibility... 13

Transcription

1 TABLE OF CONTENTS Safety Notices... 1 Handling Anhydrous Ammonia... 2 Physiological Responses to Ammonia Vapor... 4 Handling Trapped Anhydrous Ammonia... 5 System Overview... 9 Virtual Terminal (VT)... 9 Master Switch Working Set Master (WSMT) Module (Anhydrous) CAN Terminators System Requirements Performance Features Compatibility Installation Virtual Terminal Master Switch Working Set Master (WSMT) Module Cab Harness Connections System Modes Operate Mode Operate Mode Buttons Next Channel Increment Decrement Inc/Dec Reset to Target Turn On/Off Channel Master Switch On/Off Setup/Configuration Mode Setup/Config Mode Buttons Next Page Next Work Screen Control Channel Setup Ground Speed Setup Diagnostics Alarm Log System Accumulators Work Screen Configuration System Configuration Control Channel Setup Control Channel Setup Constants Type Units Preset Method Enabled Preset Method Disabled Control Mode Drive Type Drive Frequency Input Filter K Factor Channel Width Prod Level Alarm i

2 TABLE OF CONTENTS System Configuration continued Control Channel valve Calibration Max Speed Max Appl rate Ch Freq Filt Current Flow Rate NH3 Flow Calibration Application Rate Fine Tuning Channel Calibration Parameters Implement Offset Boom Output Module Configuration Boom Setup # of Output Modules Boom Width for Boom Control Boom Assignment for Boom Control Foot Switch Connection to BSM Boom Sense Configuration (non-dj switches/modules) Logic Level (1) Ground Speed Setup Source Manual Ground Speed GSPD Constant Shut Off Speed Master Switch Timeout Minimum Override implement lift Switch Ground Speed Calibration VT Aux Input/Function Assignment VT Aux Input/Function Assignment Master Switch Assigned No Master Switch Assigned Work Screen Configuration Data Items Clearing Accumulators Control Actual Channels Control Target Channels Control Rate Channels Control Scan Ground Speed Total Area Field 1 Area Field 2 Area Channels 1-2 Area Area Scan Control Feedback Scan Area Per Hour System Active Time Distance Accumulator Channel Material Accumulator Channel 1-2 Product Level Automated Guidance Status NH3 Tank Pressure Boom Status...58 ii

3 TABLE OF CONTENTS System Operation Minimum Pre-Operating Requirements Operate Screen Symbols Target Rate Increase/Decrease % Rate Preset Rate Implement Lift Switch Valve Full Open Automated Steering Navigation Task Controller Accumulators Application Rate Capacity Indicator System Information and Diagnostics Diagnostics Accumulators/Distance Screen Powered On Time Sys. Active Time Sys. Active Area Distance Information Screen Resetting NOVRAM Values Acknowledging Alarm Conditions Alarm History Alarm Log Detail Reset Alarm Log Task Controller Configuring Implement Offset (GPS) Application Rate Controlled Behind Tractor Application Rate Controlled in Tractor Front Reload Application Rates Import/Export Data Troubleshooting & Alarms Appendix A System Capacity Considerations NH3 System Flow Rates Operating Principles of Anhydrous Ammonia Characteristics Of Anhydrous Ammonia System Configuration Worksheet Work Screen Configuration Warranty...87 iii

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

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7 TABLE OF CONTENTS Safety Notices... 1 Handling Anhydrous Ammonia... 2 Physiological Responses to Ammonia Vapor... 4 Handling Trapped Anhydrous Ammonia... 5 System Overview... 9 Virtual Terminal (VT)... 9 Master Switch Working Set Master (WSMT) Module (Anhydrous) CAN Terminators System Requirements Performance Features Compatibility Installation Virtual Terminal Master Switch Working Set Master (WSMT) Module Cab Harness Connections System Modes Operate Mode Operate Mode Buttons Next Channel Increment Decrement Inc/Dec Reset to Target Turn On/Off Channel Master Switch On/Off Setup/Configuration Mode Setup/Config Mode Buttons Next Page Next Work Screen Control Channel Setup Ground Speed Setup Diagnostics Alarm Log System Accumulators Work Screen Configuration System Configuration Control Channel Setup Control Channel Setup Constants Type Units Preset Method Enabled Preset Method Disabled Control Mode Drive Type Drive Frequency Input Filter K Factor Channel Width Prod Level Alarm i

8 TABLE OF CONTENTS System Configuration continued Control Channel valve Calibration Max Speed Max Appl rate Ch Freq Filt Current Flow Rate NH3 Flow Calibration Application Rate Fine Tuning Channel Calibration Parameters Implement Offset Boom Output Module Configuration Boom Setup # of Output Modules Boom Width for Boom Control Boom Assignment for Boom Control Foot Switch Connection to BSM Boom Sense Configuration (non-dj switches/modules) Logic Level (1) Ground Speed Setup Source Manual Ground Speed GSPD Constant Shut Off Speed Master Switch Timeout Minimum Override implement lift Switch Ground Speed Calibration VT Aux Input/Function Assignment VT Aux Input/Function Assignment Master Switch Assigned No Master Switch Assigned Work Screen Configuration Data Items Clearing Accumulators Control Actual Channels Control Target Channels Control Rate Channels Control Scan Ground Speed Total Area Field 1 Area Field 2 Area Channels 1-2 Area Area Scan Control Feedback Scan Area Per Hour System Active Time Distance Accumulator Channel Material Accumulator Channel 1-2 Product Level Automated Guidance Status NH3 Tank Pressure Boom Status...58 ii

9 TABLE OF CONTENTS System Operation Minimum Pre-Operating Requirements Operate Screen Symbols Target Rate Increase/Decrease % Rate Preset Rate Implement Lift Switch Valve Full Open Automated Steering Navigation Task Controller Accumulators Application Rate Capacity Indicator System Information and Diagnostics Diagnostics Accumulators/Distance Screen Powered On Time Sys. Active Time Sys. Active Area Distance Information Screen Resetting NOVRAM Values Acknowledging Alarm Conditions Alarm History Alarm Log Detail Reset Alarm Log Task Controller Configuring Implement Offset (GPS) Application Rate Controlled Behind Tractor Application Rate Controlled in Tractor Front Reload Application Rates Import/Export Data Troubleshooting & Alarms Appendix A System Capacity Considerations NH3 System Flow Rates Operating Principles of Anhydrous Ammonia Characteristics Of Anhydrous Ammonia System Configuration Worksheet Work Screen Configuration Warranty...87 iii

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11 SAFETY NOTICES Safety notices are one of the primary ways to call attention to potential hazards. This Safety Alert Symbol identifies important safety messages in this manual. When you see this symbol, carefully read the message that follows. Be alert to the possibility of personal injury or death. Use of the word WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Use of the word CAUTION with the Safety Alert Symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Use of the word CAUTION without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in equipment damage. SAFETY NOTICES / 1

12 HANDLING ANHYDROUS AMMONIA For your own protection, it is important to carefully read, understand, and follow all safety precautions outlined in this manual when handling anhydrous ammonia. Anhydrous ammonia can be very dangerous if improperly handled. All safety procedures must be carefully observed. Serious injury is preventable when safety precautions are observed. These safety precautions are not meant as a substitute for proper training regarding the handling and application of anhydrous ammonia. Do not use or handle anhydrous ammonia without appropriate training. It is recommended that protective gloves, boots, slicker and/or pants and jacket, and checmical-splash goggles that are impervious to anhydrous ammonia are worn at all times. The system is warranted and guaranteed with only DICKEY-john recommended peripheral devices (e.g., radar ground speed sensor, valve actuators, flow meter, etc.) Other manufacturer s devices are not recommended because of unpredictable results, and in some cases can have dangerous consequences. Anhydrous ammonia can cause severe injury if improperly handled. Any person engaged in handling ammonia can reduce risk of serious accidents by observing the following: 1. DO NOT TAMPER WITH SAFETY RELIEF, EXCESS FLOW VALVES, OR OTHER SAFETY DEVICES. 2. DO NOT MODIFY ANY OF THE CONTROL SYSTEM PARTS. 3. A fail safe valve (hydraulic or electric) is required to provide shutdown capability in the event of an electrical IntelliAg failure. 4. Know the product, its characteristics, and behavior. Refer to manufacturer guidelines regarding cleaning, inspecting, maintenance, and replacement of the nurse tank and component parts such as valves and hoses. 5. Use only equipment suitable for anhydrous ammonia service, and make sure it is properly installed - never try to just get by. 6. Make regular inspections of equipment to ensure everything is fully maintained. Always perform corrective measures immediately to maintain a high level of safety. 7. Use and maintain standard protective equipment necessary to safely handle anhydrous ammonia. 8. Obtain proper training in handling and applying anhydrous ammonia. 9. Store and handle anhydrous ammonia in accordance with state and local regulations. Where no state or local regulations exist, use only 2 / SAFETY NOTICES

13 equipment that is constructed in accordance with The Fertilizer Institute Standards. 10. Ensure all ammonia is out of the system before disconnecting or disassembling any parts. Be alert for frosting which is a certain indication of trapped liquid ammonia vaporizing. Depressurize all hoses when not in use. Lack of frost does not always indicate a lack of ammonia. 11. Always repair ammonia leaks immediately. 12. Inspect hoses thoroughly before each season or when the hose has been subjected to abnormal abuse. Ensure hoses are not kinked. Check for breaks or softening in the cover, blistering, swelling, loose couplings or damage to the hose reinforcement. Correct any defects or retire the hose from service. Replace hoses as recommended by the manufacturer. 13. Always pick up a hose by the valve body or coupling, never by the valve handwheel. 14. Always stay clear of valve or hose openings, particularly safety relief valves; even when the system has been depressurized. 15. Use only proper capacity safety relief and excess flow valves - do not tamper with them or other safety devices. 16. Never use wrenches in closing handwheel operated valves. 17. Always stand on the upwind side of ammonia transfer operations. 18. Be certain to wear tight fitting safety goggles or a full-face shield and protective gloves made of rubber or other material impervious to anhydrous ammonia when transferring ammonia. 19. Be certain no person or animal is in line with the discharge before opening any ammonia valve into the air. 20. Close all valves and disconnect all hoses when transfer operations are suspended or unattended. 21. Install an automatic liquid relief (Hydrostatic) valve in any location where a possibility of liquid anhydrous ammonia could be trapped. This valve must open at a safe pressure and discharge into a safe location. 22. Be sure there is a proper shutoff valve on both sides of any point where a disconnect is made. 23. Do not assume that all ammonia is out of the system even when relief valves have been opened and there is zero pressure. Ammonia can remain in the system for several days and sometimes even weeks depending upon weather conditions. 24. Clean, service, and replace safety breakaway valves in accordance with the manufacturer's instructions. 25. Be aware that ammonia can collect in low parts. 26. Do not attempt to modify or lengthen any sensor or flow meter cables. Extension cables are available from your dealer. 27. Running the nurse tank empty or bleeding system through the flow meter may cause damage to the flow meter. SAFETY NOTICES / 3

14 PHYSIOLOGICAL RESPONSES TO AMMONIA VAPOR Concentration of ammonia in the air is measured by parts per million (ppm) and 10,000 ppm = 1%. Exposure levels tolerated by average persons can produce severe respiratory damage to others. First aid for all ammonia victims consists of fresh air and plenty of water for affected areas. The average person s response when exposed to different concentration levels of ammonia vapor are: 5 ppm - Least perceptible odor ppm - Readily detectable odor ppm - No discomfort or impairment of health for prolonged exposure ppm - General discomfort and eye tearing; no lasting effect on short exposure ppm - Severe irritation of eyes, ears, nose, throat; no lasting effect on short exposure. 1,700 ppm - Coughing, bronchia spasms. 2,000-3,000 ppm - Dangerous, less than 1/2 hour exposure can be fatal. 5,000-10,000 ppm - Serious edema, strangulation, asphyxia, rapidly fatal. 10,000 ppm - Immediately fatal. It is recommended that: A clean, five-gallon water supply is attached to the nurse tank as required by federal and state regulation. At least five gallons of easily-accessible clean water is in the vehicle used to tow an anhydrous ammonia nurse tank as recommended by the University of Minnesota Extension Series. A 16-ounce water bottle is on the person for immediate access to flush any areas of the body exposed to anhydrous ammonia. It is recommended that protective gloves, boots, slicker and/or pants and jacket, and chemical-splash goggles that are impervious to anhydrous ammonia are worn at all times. ANYONE BURNED OR OVERCOME BY AMMONIA SHOULD SEEK IMMEIDATE EMERGENCY MEDICAL ASSISTANCE. 4 / SAFETY NOTICES

15 HANDLING TRAPPED ANHYDROUS AMMONIA The Super Flow Assembly is a manufactured product of Continental NH 3 Products, therefore, the user should consult with the individual manufacturer s guidelines regarding inspection, maintenance, and useful life of any component parts. NOTE: Contact Continental NH 3 Products for Super Flow Assembly usage guidelines: 130 Yorktown Dallas, TX PH# DICKEY-john does not warrant products that are not manufactured by DICKEY-john and does not make any definitive representation regarding the useful lives of those parts. It is recommended to conduct daily inspections of hoses for kinks and defects, as well as full inspection and maintenance of those hoses and valves. Zero pressure in your applicator system does not mean that all anhydrous ammonia is out of the system. Liquid anhydrous ammonia may still be present. Frost on any part or component of the system is a positive indication of liquid anhydrous ammonia at low pressure. However, the lack of frost does not indicate a lack of anhydrous ammonia, particularly in heavy-duty hoses. IMPORTANT: It is recommended that upstream and downstream check valves are installed. Refer to the appropriate piping/plumbing component manufacturer and anhydrous ammonia literature for further details. Figure 1 Component Control System Trapped Anhydrous Super Flow Assembly Recommended Shutoff Valve (not supplied by DICKEY-john) Trapped Anhydrous Downstream Existing Regulator Recommended Shutoff Valve (not supplied by DICKEY-john) Upstream IMPORTANT: Before installation, and if it becomes necessary to replace any component of the control system, the applicator must be drained of all anhydrous ammonia. SAFETY NOTICES / 5

16 To drain the application (for installation, storage, or maintenance): 1. Disconnect the nurse tank from the applicator. 2. Lower the applicator. While pulling it through the field, open the regulator valves or place the control system in AUTO. If manifold shutoff valves are present, open them. 3. Continue driving until the applicator system shows zero pressure. Applicator knives do not smoke when raised out of the ground. 4. Open all bleed-off valves of the system to allow vapors to dispense. If liquid anhydrous ammonia is present (after a short period of time) frost may form on metallic components and a temperature change can be detected on hoses. 5. Clear the hoses by raising the low spots. If liquid anhydrous ammonia is present, a discharge will be visible through the applicator knives. Make certain you are on the upwind side of the applicator. Liquid anhydrous ammonia will evaporate from a depressurized (all valves open) system. This evaporation may take 1 day, 2 days, or several weeks depending on temperature and weather conditions. After a period of time, check the temperature from top to bottom of the Super Flow. If a temperature difference is detected, liquid anhydrous ammonia is still present and additional time is required for evaporation. If no temperature difference is detectable, the system can be stored. It is recommended that protective gloves, boots, slicker and/or pants and jacket, and chemical-splash goggles that are impervious to anhydrous ammonia are worn at all times. To remove or replace components (after completing previous steps): 6. Look for frost on the Super Flow and hoses. If none is seen, check the temperature of the hoses in question, particularly at low spots and the Super Flow. If a change in temperature is detected along a hose or from top to bottom, this indicates that liquid anhydrous ammonia is present. 7. Clear the hoses by raising the low spots. If liquid anhydrous ammonia is present, a discharge will be seen through the applicator knives. Make certain you are on the upwind side of the applicator. 8. For replacement of flowmeter, control valve, or Super Flow, it is recommended that the Super Flow be completely filled with water. With protective clothing and goggles in place, carefully remove one of the pressure relief valves on the Super Flow. Install a 1/4 inch pipe nipple (4-6 inches in length) in the pressure relief valve port. Slide a garden hose over the 1/4 inch pipe nipple and clamp it in place. 6 / SAFETY NOTICES

17 IMPORTANT: When water mixes with anhydrous ammonia, boiling will occur and may cause vapor and water to shoot out the knives and the nurse tank hose end. Make sure the nurse tank hose is pointed in a safe direction. If water runs out of the nurse tank hose before both chambers of the Super Flow are filled, it may be necessary to close the shutoff valve on the hose. Make certain you are a safe distance on the upwind side and that no person or animal is immediately downwind. 9. Slowly turn on the water. Allow the applicator system and the Super Flow to completely fill with water. Turn off the water and remove the garden hose. Disassemble the components as required. 10. Reinstall the pressure relief valve. SAFETY NOTICES / 7

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19 OPERATOR S MANUAL SYSTEM OVERVIEW The DICKEY-john system controls the application of anhydrous ammonia (NH3) (rate is displayed in lbs of N/Ac). The IntelliAg is designed to ISO CAN communications providing the capability of communicating with other manufacturer s ISO compatible equipment. The IntelliAg consists of: NOTE: Examples shown throughout this manual depict display screens of the 10 Virtual Terminal display. 5 Virtual Terminal or a 10 Virtual Terminal Master Switch Working Set Master Module CAN Terminators VIRTUAL TERMINAL (VT) A 5 or 10 Virtual Terminal provides user interface with the IntelliAg system used for output and input of data. Reference the VT operator s manual for setup and configuration instructions. Figure 2 5 or 10 Virtual Terminal SYSTEM OVERVIEW / 9

20 MASTER SWITCH Figure 3 Master Switch The Master Switch allows the user to start and stop product application through a single switch. The two switch positions are ON and OFF. The normal operating position for field application is ON. In this position, ground speed controls the application rate. When ground speed is reduced to zero, all application ceases. The OFF position inhibits all product flow. When set to the OFF position, the system shuts off for safety and travel purposes. Setup and configuration of the system is accomplished when the Master Switch is in the OFF position. The Master Switch is also housed inside the cab of the tractor. WORKING SET MASTER (WSMT) MODULE (ANHYDROUS) Figure 4 Working Set Master Module The Working Set Master (WSMT) module houses the system s primary interface device. All system parameters, constants and memory are stored in the WSMT. The WSMT has two channels for Anhydrous control. In addition, the WSMT can accept inputs from 1 lift switch and 1 ground speed sensor. The WSMT module uses a 30 and 18-way connector with a jackscrew to secure the connector to the module. The WSMT is typically mounted on the implement. 10 / SYSTEM OVERVIEW

21 CAN TERMINATORS CAN Terminators are necessary for proper communication between each component of the system. One terminator is located on the cab harness, approximately 30 inches from the Virtual Terminal connector. One terminator plugs into the WSMT module harness. Figure 5 CAN Terminator SYSTEM OVERVIEW / 11

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23 SYSTEM REQUIREMENTS The minimum requirements to operate the IntelliAg NH 3 system consist of: Virtual Terminal Master Switch Working Set Master Two CAN terminators NH3 cooling tower NH3 control valve at NH 3 flow meter TECU (10 VT only) PERFORMANCE FEATURES Monitors ground speed Easy and flexible configuration User-definable view of functions including: control actual rates 1-2 control target rates 1-2 control rate 1-2 control scan ground speed total area field area 1-2 channel area 1-2 area scan control feedback scan area per hour system active time distance accumulator channel material accumulation channel product level NH3 tank pressure COMPATIBILITY Compatible ONLY with DICKEY-john sensors IMPORTANT: DICKEY-john does not warranty or recommend the use of other manufacturer s valves and/or sensors with the IntelliAg NH 3 control system. SYSTEM REQUIREMENTS / 13

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25 INSTALLATION VIRTUAL TERMINAL Reference the Virtual Terminal (VT) operator s manual for installing the VT to the tractor cab. Once the Virtual Terminal has been mounted, connect the Tractor (Cab) Harness as illustrated in (Figure 10) or (Figure 11). Figure 6 Dj 5 and 10 Virtual Terminals MASTER SWITCH 1. Install the master switch within easy reach of the operator. The switch can be attached to any convenient location using tie wraps, tape, Velcro stripping, etc. 2. Once mounted, connect the master switch to the tractor (cab) harness as illustrated in (Figure 10) or (Figure 11). Figure 7 Master Switch INSTALLATION / 15

26 Figure 8 Working Set Master Module WORKING SET MASTER (WSMT) MODULE 1. Select an area on the implement to mount the WSMT that allows for easy hookup and access. Use the enclosure as a template to mark the location of the mounting holes. Drill four 9/32 inch diameter holes where marked. IMPORTANT: Do not use the enclosure as a guide when drilling. Do not overtighten nuts as this may damage the mounting tabs of the enclosure. The WSMT may be mounted in any of the following orientations: Figure 9 Acceptable Orientation PREFERRED ACCEPTABLE ACCEPTABLE Do not install the module in any orientation other than shown in (Figure 9). The connection wires must not be mounted upward, as moisture can collect inside the unit and damage the circuits. 2. Mount with the label inside of module facing out. 16 / INSTALLATION

27 3. Connect any additional adapter harnesses to the module harness. The WSMT Module harness can accept the following adapter harnesses: Actuator Harness contains: 2 Control channel feedbacks 1 Ground speed input 1 Implement switch input In addition, a pair of 6-pin connectors are available for Servo connection. Install sensors, valves, etc. per the instructions included with the items. Install the Servo valve assembly and feedback sensor for each control loop and connect the devices to their respective inputs on the harness, making certain to match Servo 1 with FB 1, Servo 2 with FB 2. Secure any unused and excess cable lengths where necessary. Refer to (Figure 12) for additional information. INSTALLATION / 17

28 CAB HARNESS CONNECTIONS The following diagrams illustrate cab harness layout and connections for DICKEY-john 5 and 10 Virtual Terminals. Figure 10 Cab Harness Layout and Connections (5 Virtual Terminal) Battery + - Chassis Ground System Power Harness Tractor Cab Harness CAN Terminator Virtual Terminal To Implement CAN Harness Ignition Connect to switched +12VDC NOTE: This wire must be connected to switched +12VDC Master Switch S1 Radar Speed Sensor (CAN Ground input when connected to cab harness) Radar can also be connected to WSMT. 18 / INSTALLATION

29 NOTE: The ignition lead must be connected to switched +12VDC for the system to power properly. 5 VIRTUAL TERMINAL CAB HARNESS CONNECTIONS 1. Connect the power leads directly to the battery. 2. Connect the ignition wire to a switched +12VDC. 3. Connect the Chassis Ground lead to a bare point of the cab frame that offers a good chassis ground connection. 4. Connect the Master Switch, CAN Terminator and Radar Speed Sensor to their respective connectors on the cab harness. If the Speed Sensor is to be connected to the WSMT, do not connect anything to the Speed Sensor connector on the Cab Harness. INSTALLATION / 19

30 Figure 11 Implement Harness Connections (10 Virtual Terminal) Battery + - System Power Harness Tractor Cab Harness A CAN Terminator Chassis Ground Tractor ECU S1 RS232 GPS Virtual Terminal To Implement CAN Harness Ignition Connect to switched +12VDC NOTE: This wire must be connected to switched +12VDC Master Switch S1 Radar Speed Sensor (CAN Ground input when connected to cab harness) Radar can also be connected to WSMT. 20 / INSTALLATION

31 NOTE: The ignition lead must be connected to switched +12VDC for the system to power properly. 10 VIRTUAL TERMINAL CAB HARNESS CONNECTIONS Connect the power leads directly to the battery. 1. Connect the ignition wire to a switched +12VDC. 2. Connect the Chassis Ground lead to a bare point of the cab frame that offers a good chassis ground connection. 3. Connect the Master Switch, CAN Terminator, Radar Speed Sensor, GPS, Tractor ECU, Task Controller to their respective connectors on the cab harness. If the Speed Sensor is to be connected to the WSMT, do not connect anything to the Speed Sensor connector on the Cab Harness. INSTALLATION / 21

32 Figure 12 Implement Harness Connect harnesses and accessory devices as shown. Verify that Servo Valves have a properly connected feedback sensor. Connect to Cab Harness. Implement CAN Breakaway Harness X (multiple lengths) NOTE: Connect the WSMT Actuator Harness to the mating connectors of the WSMT Module Harness WSMT Module WSMT Module Harness Accessory Sensor Connection Flow Meter Sensors x 2 (Channel 1-2 Feedback) CAN Terminator (Connect CAN terminator if this is the last module on the CAN bus) Servo Valves Channel 1-2 Control WSMT Actuator Harness Implement Lift Sensor Labeled IMP LIFT If no Implement Lift Sensor is used, connect the IMP LIFT leads together Radar Speed Sensor Labeled GND Speed 22 / INSTALLATION

33 SYSTEM MODES The Virtual Terminal has two modes of operation: Operate Setup/Configuration The position of the master switch determines which mode is selected. OPERATE MODE When the master switch is in the ON position, the Virtual Terminal (VT) is in OPERATE mode. In this mode, all enabled system components and control channels are operational, as well as all monitoring functions and system accumulators. Figure 13 OPERATE Mode Default Display OPERATE MODE BUTTONS NEXT CHANNEL The Next Channel button selects the next available channel to be active and viewable. The active channel may be set to ON or OFF by selecting the Turn On/Off Channel button. The Target Rate can be adjusted by using the Inc/Dec buttons. The Next Channel button displays the next available channel information. This key is visible only when multiple channels have been configured. SYSTEM MODES / 23

34 NITROGN NITROGN INCREMENT The Increment button increases the active channel s target rate by the amount specified in the Inc/Dec% or rate table setup for that channel. Increment can be pressed several times to increase the target rate by the specified amount for every actuation, until the Max Rate value is reached. The active channel/material is displayed in the button text. For additional information, refer to CONTROL CHANNEL CONFIGURATION. DECREMENT The Decrement button decreases the active channel s target rate by the amount specified in the Inc/Dec% or rate table setup for that channel. Decrement can be pressed several times to reduce the target rate by the specified amount for every actuation, until the Min Rate value is reached. The active channel/material is displayed in the button text. For additional information, refer to CONTROL CHANNEL CONFIGURATION. INC/DEC RESET TO TARGET The Inc/Dec Reset to Target button is used to return the active channel to the original target rate. This button is only available for channels that are active and have had the target rate adjusted using the Increment or Decrement buttons. The active channel/material is displayed in the button text. This key is visible only when a change has been made to the target rate. TURN ON/OFF CHANNEL The Turn On/Off Channel buttons turn the active channel(s) ON and OFF, respectively. Channels that are set to OFF will not operate when the Master Switch is set to the ON position. Note that turning a channel OFF is not the same as disabling a channel in the Channel Setup mode. The active channel is displayed in the button text. If the button display indicates OFF, this is the action that is performed when pressed. MASTER SWITCH ON/OFF The Master Switch On and Off button operates as a master switch for Auxiliary items when a physical Master Switch is not present. Pressing the Master Switch button toggles the system control on and off. 24 / SYSTEM MODES

35 SETUP/CONFIGURATION MODE When the master switch is in the OFF position, the VT is in SETUP/ CONFIGURATION mode. In this mode, all control and monitoring functions cease. System configuration and parameter setup functions are enabled. Figure 14 SETUP/CONFIGURATION Mode Additional buttons for system configuration and parameter setup will appear when the VT is in Setup/Configuration mode. SETUP/CONFIG MODE BUTTONS NEXT PAGE The Next Page button only displays when there are 6 or more buttons on the active window and may look different depending on the Virtual Terminal attached. NEXT WORK SCREEN The Next Work Screen button displays the next configured screen. The number to the left of the graphic identifies the current screen. The number on the right identifies the next screen to be displayed. This key is visible only when multiple work screens have been configured. CONTROL CHANNEL SETUP The Control Channel Setup button accesses the Control Channel Setup screen. All user-defined control channel constants are defined on this screen. SYSTEM MODES / 25

36 GROUND SPEED SETUP The Ground Speed Setup button accesses the Ground Speed Setup screen. Ground speed is the rate in MPH (Km/h) as measured by the ground speed sensor. For additional information, refer to GROUND SPEED CALIBRATION. DIAGNOSTICS The Diagnostics button accesses the Diagnostics screen. Various system operating parameters are displayed on this screen. There is no user-entered data on this screen. For additional information, refer to DIAGNOSTICS. ALARM LOG The Alarm Log button accesses the Alarm Log screen. An account of the previous alarms issued is stored here. There is no user-entered data on this screen. For additional information, refer to ACKNOWLEDGING ALARM CONDITIONS. SYSTEM ACCUMULATORS The System Accumulators button accesses the System Accumulators screen. Accumulators for Powered On Time, System Active Time, Area, and Distance are on this screen. There is no user-entered data on this screen. For additional information, refer to ACCUMULATORS/SEED COUNT/DISTANCE SCREEN. WORK SCREEN CONFIGURATION The Work Screen Configuration button accesses the Work Screen Configuration Setup screen. Users have the option to customize the Virtual Terminal to display any combination of data items available. The system allows for up to three individual display screens to be customized. All work screen configuration is established on this screen. For additional information, refer to WORK SCREEN CONFIGURATION. 26 / SYSTEM MODES

37 SYSTEM CONFIGURATION NOTE: Refer to individual installation instructions to ensure system component installation is achieved accurately. CONTROL CHANNEL SETUP Control Channel Setup allows configuration of 2 independent control channels for Anhydrous. A control channel identified as Disabled indicates the channel is not in use. Control channel parameters that can be configured include: Type Preset Method Target Rate Max and Min Rates Inc/Dec % Drive Frequency Input Filter K-Factor Channel Width Prod Level Alarm Control Channel button To establish a Control Channel: 1. From the Main Operate screen, press the Control Channel button to access the Control Channel Setup screen. To configure a second control channel, press the Next Channel button. Figure 15 Control Channel Setup Next Channel button Auto Servo 1 SYSTEM CONFIGURATION / 27

38 CONTROL CHANNEL SETUP CONSTANTS TYPE Type defaults the material application as Anhydrous Control. Type also can be changed to Disabled for a channel not in use. UNITS Units shows the primary and secondary display units. Primary display will be in lbn/ac with a secondary instrument showing lbn/hr. Units setting cannot be changed. PRESET METHOD ENABLED The Preset Method Table allows user-defined target rates to be entered. When enabled, target rates can be adjusted from the Main Operate screen using the Increment and Decrement buttons or up to 10 preset target rates can be configured. Figure 16 Control Channel-Preset Method Enabled PRESET RATE PRESET RATE Enabled Nitrogn 1 With Preset enabled, target rate adjusts based on the Preset rate entered at the Control Channel screen. PRESET METHOD DISABLED When the Preset Method is disabled, the target rate on the Main Operate screen will increase/decrease when the Material Increment/Decrement buttons are pressed per the rate set on the Control Channel screen. 28 / SYSTEM CONFIGURATION

39 Figure 17 Control Channel-Preset Disabled NITROGN 1 With Preset disabled, target rate adjusts based on the Inc/Dec % rate set at the Control Channel screen. NITROGN 1 NITROGN 1 NITROGN 1 CONTROL MODE Control Mode defaults to AUTO and is nonselectable. The Control Channel calculates application rates based on ground speed and implement position. DRIVE TYPE Servo A ball valve that is driven by an electric motor gearbox and is installed in the main product delivery line. PWM (Pulse Width Modulation) A proportional valve regulating hydraulics and varies the oil flow to a hydraulic motor proportioned to electric current supplied. This type of valve consists of a flow cartridge and coil assembly. DRIVE FREQUENCY Drive Frequency specifies the frequency for the control signal that is being used. The recommended setting for a DICKEY-john Servo valve is 40 Hz. INPUT FILTER The Input Filter provides a setting for the amount of filtering applied to the feedback frequency feedback of the Control Channel. SYSTEM CONFIGURATION / 29

40 IMPORTANT: It is NOT recommended that the Input Filter be manually altered. Any adjustments could result in the channel not operating properly. If adjustments are made a valve calibration must be performed. K FACTOR K Factor specifies how many pulses are produced by the sensor per cubic inch of NH3 that passes through the flowmeter. The flow meter constant is a calibration number and can be found on the side of the flow meter. If known, the K Factor can be entered manually. CHANNEL WIDTH Channel Width requires a manual entry of the width of the channel coverage area. PROD LEVEL ALARM The product level alarm sets the weight to trigger an alarm alerting of low tank levels. The entered value is in lbs of N. 30 / SYSTEM CONFIGURATION

41 CONTROL CHANNEL VALVE CALIBRATION Control Channel Valve Calibration button The Control Channel Valve Calibration screen sets the machine system parameters and should be performed for best results. Each control channel that is enabled requires a valve calibration. Press the Control Channel Calibration button to access the Control Channel Calibration screen. IMPORTANT: A valve calibration is required before applying material in the field. The system will not operate properly and application rates will fluctuate considerably if a valve calibration is not performed. Figure 18 Control Channel Calibration Screen Nitrogn 1 When the START key is engaged, the machine will become operational and dispense NH3. All necessary precautions must be taken to ensure user safety. Failure to practice all necessary caution may result in serious injury or death. To perform a Control Channel Valve Calibration: 1. Enter a maximum speed and maximum application rate in the input boxes on the Control Channel Calibration screen. 2. Implement should be in the lowered position. 3. Begin moving the tractor at a speed greater than 1 mph. The tractor must be moving for a calibration to begin. 4. Press the Start button. 5. Turn the master switch to the ON position. The valve calibration will immediately start. SYSTEM CONFIGURATION / 31

42 NOTE: A Max Rate Exceeded indication will occur in calibration mode if the system cannot obtain the max flow rate. Reduce the maximum speed or maximum application rate entered to resolve this alarm. The calibration can take a few seconds up to several minutes. Each calibration step is monitored on the lower left corner of the display. When the calibration is complete, the control shuts down automatically. All calibration data is automatically stored. MAX SPEED A maximum speed entered in mph that will be driven while applying Anhydrous in the field. MAX APPL RATE The maximum application rate to be applied this season entered in lbs N/ac. CH FREQ FILT Channel Frequency Feedback provides automatic feedback in pulses per second from the Anhydrous flow meter. CURRENT FLOW RATE Automatic feedback of the current flow rate calculation (lbs N/hr) based on the current K-Factor. 32 / SYSTEM CONFIGURATION

43 NH3 FLOW CALIBRATION Accuracy of the control system can be affected by many factors. Accuracy should be checked after first installing the system and after starting the system for the first time each season. To check accuracy: 1. Select a field where the area is known to be accurate (preferably 10 acres or more). 2. Weigh the nurse tank and record the number. 3. Apply product to the field as in normal operation. 4. When finished, weight the nurse tank and record the number. 5. To determine the amount of product applied per acre: Tank weight at start (minus) tank weight at finish acres covered = pounds of NH applied per acre 3 Pounds of NH applied per acre x.82 = pounds of actual Nitrogen per acre 3 6. To determine percent error: Actual lbs per acre (minus) desired lbs per acre desired lbs per acre x 100 = % error For example: Tank weight at start 4200 pounds Tank weight at finish 1900 pounds Acres covered 10 Desired pounds per acre 200 actual nitrogen = 230 pounds of NH 3 per acre 230 lbs of NH3 applied per acre x.82 = lbs of actual nitrogen per acre = x 100 = -5.7% error APPLICATION RATE FINE TUNING If it is found over a period of time that a small (less than 10%) application rate error is consistently under or over the target, the control system can be fine tuned. These small errors can be the result of the anhydrous ammonia applicator variations. 1. Determine the new Flowmeter Constant as follows: New Flow Meter Constant = (Old Flow Meter Constant) Desired APR Actual APR For example, if the application rate was programmed for 200 lbs per acre and over a period of time the actual application was determined to be 208 lbs per acre, an adjustment could be made to the Flowmeter Constant value using the formula illustrated above. SYSTEM CONFIGURATION / 33

44 Desired APR = 200 Actual APR = 208 Old Flowmeter Constant = 2.15 (2.15) 200 = 2.15 x.9615 = or Control Channel button The new Flowmeter Constant is The new Flow Meter Constant (K-Factor) can be entered at the Control Channel screen. Raise the Flowmeter Constant to RAISE the amount of material applied. Lower the Flowmeter Constant to LOWER the amount of material applied. 34 / SYSTEM CONFIGURATION

45 CHANNEL CALIBRATION PARAMETERS Calibration Parameters button The Channel Calibration screen provides system information automatically input after a valve calibration is performed. Data on the Calibration Parameters screen should NOT be changed unless instructed by an authorized service technician! Figure 19 Calibration Parameters IMPLEMENT OFFSET Implement Offset button An Implement Offset button will display only for those applications using Task Controller. Refer to the Task Controller section for setup instructions. SYSTEM CONFIGURATION / 35

46 NOTE: Refer to following page for NH3 warnings. BOOM OUTPUT MODULE CONFIGURATION For NH3 applications using boom sense or boom control, a module s position, number of outputs, and boom assignment must be defined: Three screens require inputs for boom control operation: Boom Setup screen Boom Width screen Boom Assignment screen Boom Setup button BOOM SETUP The Boom Setup screen identifies how many boom output modules are connected to the system and allows assignment of boom outputs and boom sections to each module. The Boom Setup screen displays Module address Type Number of outputs Boom section assignment To Assign Boom Output Modules: 1. At the Module Configuration screen, press the Boom Setup button. 2. Enter # of outputs (shutoffs) assigned to each module in the # of Out input box. 3. If a non-dickey-john auto section control system is installed, press the Enable ISO Section Control input box. A checkmark indicates the selection is enabled. This selection will not appear if the DICKEY-john auto section system is installed and used. Figure 20 BOM Setup Screen Enable ISO Section Con Enable if a non DICKEY-john section control box is installed. 36 / SYSTEM CONFIGURATION

47 # OF OUTPUT MODULES Number (#) of Outputs displays the total number of output shutoffs are connected to the system. The Output Numbers (#) value is automatically established for proper numbering sequence for each output based upon the module address value. BOOM SWITCH/NH3 SAFETY PRECAUTION When operating NH3 with a boom switch module the following steps should be followed to ensure that NH3 is not released improperly in an unsafe area. Any trapped NH3 will release approximately 4 seconds after the boom switch module master switch is turned on. 1. Vehicle should be outside in a well ventilated area. 2. Ensure the boom switch module master switch is OFF prior to power up of tractor. 3. All persons or animals should be a safe distance on the upwind side from the vehicle before turning the boom switch module master switch ON to avoid release of NH3. Refer to additional safety instructions when using NH3 in the Safety Notices section of this manual. Figure 21 Trapped NH3 Super Flow Assembly Trapped Anhydrous Existing Regulator Trapped Anhydrous Recommended Shutoff Valve (not supplied by DICKEY-john) Upstream Downstream NH3 boom solenoid section shutoff valve opens approx. 4 seconds after boom section control master switch is turned on and will release any trapped NH3 SYSTEM CONFIGURATION / 37

48 BOOM WIDTH FOR BOOM CONTROL Boom Width button Boom Width identifies which control channel is associated with a boom section and the width of each section. An additional screen will appear for configuring more than 12 boom sections. A maximum of 24 sections can be assigned to a channel. To Enter Channels and Width: 1. At the Boom Setup screen, press the Boom Width button. 2. Press the Channel input boxes to assign a section to a control channel. 3. Press the Width input box to enter the section width in inches. NOTE: If the control channel input box does not allow entry of a control channel number, the control channel is configured as an RPM control and cannot be assigned to a boom section. Figure 22 Boom Width Screen / SYSTEM CONFIGURATION

49 BOOM ASSIGNMENT FOR BOOM CONTROL Boom Assign button Boom Assignment assigns each boom section to a switch on the DICKEY-john boom switch module. Channel Linking allows control channels to be linked together so that all linked sections will turn on or off at the Main Work screen when or if a section is shut off. To Assign and Link Boom Sections: 1. At the Module Configuration screen, press the Boom Assign button. 2. Press the Switch input boxes to assign a section to a switch. The channel assigned to the section will have a check mark in the Link Channel input box indicating channel assignment and cannot be changed on this screen, only on the Boom Width screen. 3. To link other active channels to a switch, press the appropriate Link Channel input box. Example: The first screen in (Figure 23) depicts the default setting of channel 1 linked to switch 1 and section 1 with no additional linked control channels. The second screen depicts channel 1 and channel 2 linked to switch 1 and section1. Channels 1 and 2 will turn on and off simultaneously when switch 1 is turned on and off. Figure 23 Boom Assignment Screen Channel 2 linked to switch 1 SYSTEM CONFIGURATION / 39

50 NOTE: The harness can also be connected to an existing cab/joystick switch that is more conviently located. FOOT SWITCH CONNECTION TO BSM On air machines, utilizing boom shutoff sections controlled by the DICKEY-john boom switch module (BSM), the foot switch can be wired into the BSM and used as a master boom on/off switch. While operating, an alarm condition will occur if the master switch is off for more than 5 to 10 seconds and ground speed is greater than zero. An Alarm Cancel button allows the alarm to be deactivated during the current power cycle. Figure 24 BSM Connection to Foot Switch Direct connection to foot switch Foot Switch cable part number connects a customer-supplied foot switch to the rear connector of the BSM. Figure 25 Foot Switch Cable 40 / SYSTEM CONFIGURATION

51 BOOM SENSE CONFIGURATION (NON-DJ SWITCHES/MODULES) Boom Sense Setup button The Boom Sense Configuration button only appears when the system is utilizing non Dickey-john boom switches and modules to control section on/ off. The switches must be identified on the Boom Sense Configuration screen and assigned to a control channel before boom sections can be turned on and off during operation. When using a non DICKEY-john section control box, the system is only detecting if the section is on or off based on a high or low input on the boom sense lines located on the accessory harness (maximum 5 sense lines). Five boom sections can be assigned to a WSMT. Assign Boom Switches to Control Channels: 1. Press the Boom Sense Setup button to display the Boom Sense Setup screen. 2. Press the Section Sense input boxes to assign sections to control channels. A checkmark indicates section/channel assignment. To unselect, press the checkmark to deselect. 3. Press the Logic Level input box and select the desired sensor polarity as Active Low (0 volts) or Active High (12 volts) to control sections by channel. 4. Enable Master Section (IMP LIFT) if using an existing master section sense switch to turn on/off all boom sections. This can also be used to shut off control channels when boom sections are turned on/off. The master section switch must be connected to the implement lift or test switch input. 5. Press the Logic Level input box and select the desired sensor polarity as Active Low or Active High of the master section switch. (Figure 26) indicates that channel 1 is assigned to boom section 1; channel 2 is assigned to boom section 2 and 3; channel 3 is not assigned to any channel. NOTE: Implement Lift on the Speed Set screen should be disabled. Figure 26 Boom Sense Configuration (non-dickey-john) Sets the logic level for individual boom sense sections Sets the logic level for the Master Section switch ENABLED Enable when using a master section switch to shut booms on/off. The master section switch must be connected to the implement lift or test switch input. SYSTEM CONFIGURATION / 41

52 Screen Config button 6. To view the boom section indicator on the Main Operate screen, the Boom Status data item found at the Work Screen Configuration screen must be selected. Press the Screen Config button to view Work Screen Configuration and to select the Boom Status data item. 7. In the desired location to appear on the Main Operate screen, press the yellow input box to select Boom Status. 8. Press the Work Screen button to return to the Main Operate screen. Figure 27 Work Screen Configuration Screen Work Screen button Select Boom Status data item to view on Main Operate screen LOGIC LEVEL (1) Logic Level sets the active state of the boom section switches as Active Low (0 Volts) or Active High (12 Volts). This functionality allows flexibility to connect boom section shutoffs that are active by supplying 12 volts to open or close. Active High Set the active state to High signifying that the boom section is ON when 12 volts is required to open boom shutoff valves. Active Low Sets the active state to Low signifying that the boom section is ON when 0 volts is required to open boom shutoff valves. IMPORTANT: Boom sections appear in black on the Main Work screen when the switches are turned ON and the logic level is set to the correct polarity. If boom sections appear in white and sections are open, return to the Boom Configuration screen and change the logic level. 42 / SYSTEM CONFIGURATION

53 Figure 28 Logic Level 3 Boom on/ active with correct Logic Level 1 2 Boom off/ inactive with incorrect Logic Level SYSTEM CONFIGURATION / 43

54 GROUND SPEED SETUP Ground Speed Setup button Ground Speed Setup determines: Input source and type of ground speed sensor being used Manual default ground speed (only displays when manual is selected as source). Shutoff speed Minimum override Master switch timeout Implement lift switch status NOTE: IntelliAg system ground speed is independent of the TECU ground speed. From the Main Operate screen, press the Ground Speed Setup button to access the Ground Speed Setup screen. Figure 29 Ground Speed Setup Screen The following data items may be edited: SOURCE Source selects the type of ground speed sensor being used and where the sensor s input is on the system. MANUAL Sets the system to operate using a fixed internally generated ground speed. No ground speed sensor is required when using the Manual setting. RELUCT FREQ Used when ground speed is provided by a reluctance (2-wire) type sensor connected to the actuator harness. DIGITAL FREQ Used when ground speed is provided by a radar/digital (3-wire) type sensor connected to the actuator harness. 44 / SYSTEM CONFIGURATION

55 NOTE: Manual ground speed can only be entered if the source is changed to MANUAL. CAN GROUND Used when ground speed is provided by a radar/digital (3-wire) type sensor connected to the cab harness or if radar/forward ground speed is available on the CAN bus. CAN WHEEL Used when wheel speed data is available on the CAN bus. This source does not compensate for slippage, therefore, misapplication may occur with this source depending on conditions. MANUAL GROUND SPEED Manual Ground Speed can be used in the event of a failure of the ground speed sensor being used. This is a fixed, internally generated ground speed that will cause the system to operate when the Master Switch is ON at the speed that has been programmed. This value can be set to any speed within the delivery capabilities of the system. GSPD CONSTANT GSPD Constant is the value representing the pulse count produced by the ground speed sensor over a 400 distance. Refer to GROUND SPEED CALIBRATION for additional information. SHUT OFF SPEED Shut Off Speed indicates the minimum ground speed allowed before the system shuts off total operation. MASTER SW TIMEOUT Master Switch Timeout determines the length of time before the system disables the operate function after ground speed is 0 (zero) if the Master Switch remains in the ON position. After the delay time elapses, an alarm is issued stating that the Master Switch must be toggled OFF/ON before the system will restart. MINIMUM OVERRIDE Minimum Override takes over when actual ground speed is below the designated value. The control will operate at this speed until actual ground speed rises above the minimum override speed, or the actual speed drops below the shutoff speed. IMPLEMENT LIFT SWITCH If an implement lift switch is used, the implement lift status must be enabled at the Ground Speed Setup screen. While operating, an alarm condition will occur if the Master Switch is off for more than 5 to 10 seconds, the implement is down, and ground speed is greater than zero. An Alarm Cancel button allows the alarm to be deactivated during the current power cycle. If an implement lift switch is not required, this function should be disabled. SYSTEM CONFIGURATION / 45

56 NOTE: Older DICKEY-john ground speed calibrations had a default value of 6096 which is the nominal pulse count for the radar speed sensor. IntelliAg ground speed equipment has a default value of 12,192. To convert older ground speed constants, multiply the recorded value by two for an approximate conversion. GROUND SPEED CALIBRATION Ground speed is the rate in MPH (Km/h) as measured by the ground speed sensor. The number reflects the number of pulses generated by the ground speed sensor while traveling a distance of 400 feet (100 meters). IMPORTANT: It is imperative to get an accurate ground speed reading, as this reading directly impacts the accuracy of Population, Area Accumulation, and Application Rate Control. Press the Ground Speed Calibration button to access the Ground Speed Calibration screen. Figure 30 Ground Speed Calibration Screen Ground Speed Calibration button STOP To perform the initial ground speed calibration: 1. Carefully measure an exact 400 foot (100 meter) course, clearly marking the start and finish points. 2. With the tractor moving between 2 and 5 MPH (3.2 and 8 Km/h), press the Start button when the tractor is even with the designated start point. The display showing the ground speed calibration will zero and begin counting ground speed pulses. 3. When the tractor is even with the designated finish point, press the Stop button. The new calibration number will be displayed on the center of the screen. 4. To ensure accuracy, record the number and repeat this process two additional times. Average the three numbers recorded. 5. Enter the average calibration number. 6. Save the desired settings. 46 / SYSTEM CONFIGURATION

57 NOTE: For Virtual Terminals, other than DICKEY-john, refer to the manufacturer s VT operator s manual for auxiliary assignment. 10 VT AUX INPUT/FUNCTION ASSIGNMENT The Auxiliary Input/Function Assignment screen configures the system s Master Switch input to the TECU so that it will work with the IntelliAg control function. IMPORTANT: On initial powerup, a Master Switch Assignment alarm activates requiring a switch assignment. If the Master Switch is not configured, the Master Switch Assignment alarm will activate at each power cycle until an auxiliary assignment is made and will default to the Master Switch button to activate auxiliary inputs. Having a master switch installed in the tractor cab is the preferred method for auxiliary input; however, a Master Switch button will be assigned and appear on the Work Screen if no assignment is made. Figure 31 Aux Input/Function Assignment Screen VT button Auxiliary Assignment button Enter button To assign the master switch to the IntelliAg: 1. Press the VT button. 2. Press the Auxiliary Assignment button. 3. At the Function box, use the right or left arrows to select the desired function (Control Channel icon). 4. At the Input box, use the right or left arrows to select the desired input (Tractor ECU Master Switch). 5. Press the Enter button to accept. No Auxiliary Inputs Available appears on the screen if the Tractor ECU is not connected. When assigned, this line will disappear. No Auxiliary Functions Available appears on the screen if the IntelliAg system is not connected. When assigned, this line will disappear. SYSTEM CONFIGURATION / 47

58 5 VT AUX INPUT/FUNCTION ASSIGNMENT The Auxiliary Input/Function Setup screen configures the location of the system s master switch. For proper assignment, the master switch must be configured correctly. An installed master switch located in the tractor cab is the preferred method for auxiliary input; however a Master Switch button on the Virtual Terminal is available if there is no master switch installed in the cab. On initial powerup, a Master Switch Assignment alarm activates requiring action (Figure 32). Press either the Master Switch button or Press the No Master Switch button ESC Figure 32 Master Switch Assignment Alarm! Master Switch Assignment Alarm Master switch assignment is invalid Master Switch No Master Switch Aux Aux Input/Function Setup button If physical auxiliary switch is available Press softkey #1 to accept physical auxiliary switch available and then correct the assignment. If no physical auxiliary switch is available Press softkey #2 to accept NO physical auxiliary switch available Installed Master Switch button No Master Switch button IMPORTANT: If the master switch is not configured, the Master Switch Assignment Alarm will activate at each power cycle until an auxiliary assignment is made and will default to the Master Switch button to activate auxiliary inputs. MASTER SWITCH ASSIGNED If assigning a Master Switch, the Virtual Terminal must be configured to acknowledge the assignment. To Configure an Installed Master Switch: 1. Press the ESC key 2 times to activate the Virtual Terminal Setup screen. 2. Press the Auxiliary Input/Function Setup button to access the Auxiliary Input/ Function Setup screen (Figure 33). 48 / SYSTEM CONFIGURATION

59 2 2 OPERATOR S MANUAL Figure 33 Auxiliary Input/Function Setup Screen Aux Input Setup softkey Default X Cancel 3. Navigate to the configuration screen by pressing the Auxiliary Input Setup button. 4. Press the Default button. A Master Switch Connection icon will appear on the screen indicating that the Master Switch is to be connected to the tractor cab harnesses Master Switch connector (Figure 34). 5. Press the OK button to save the configuration and return to the Aux Input/Function Setup screen. 6. Press and hold the ESC button for one or more seconds to return to the Virtual Terminal Setup screen. Figure 34 Aux Input Configuration Screen Aux Up Down The Master Switch Connection icon may appear automatically on this screen, or may appear after the DEFAULT softkey has been pressed. Default Clear OK Cancel SYSTEM CONFIGURATION / 49

60 Master Switch ON button NO MASTER SWITCH ASSIGNED When the No Master Switch icon is pressed, the Virtual Terminal assigns a Master Switch button to function as the Auxiliary ON and OFF keys. The Main Operate screen will display with a Master Switch ON button at the top of the screen. Toggling between the Master Switch ON and OFF buttons cycles the system control ON and OFF. Master Switch OFF button Figure 35 Main Operate Screen with VT Master Switch Configured Pressing the softkey toggles between ON and OFF IMPORTANT: As a safeguard, when the Master Switch ON button is pressed, a Master Switch button Activation alarm must be acknowledged before equipment operates, refer to (Figure 32). This alarm occurs the first time the Master Switch button is pressed after power up. 50 / SYSTEM CONFIGURATION

61 WORK SCREEN CONFIGURATION Work Screen Config button A variety of data items are selectable at the Work Screen Configuration screen for viewing in any position on the Main Operate screen. The display is functionally divided into 2 columns and 6 rows. Press the Work Screen Configuration button to access the Work Screen Configuration screen. Any data item can be placed in any position. Duplicate data items can be configured on a single display if desired. Up to three display screens can be configured. Some items selected for the work screen will take up one entire row. After these items have been selected, the new settings display on the Main Operate screen. Figure 36 Work Screen Configuration Screen NOTE: Some items selected for the work screen will take up one entire row. Refer to DATA ITEMS for a detailed description of each item and the associated display images. In order to configure the second and third display screens, select the Next Work Screen button. Next Work Screen button SYSTEM CONFIGURATION / 51

62 52 / SYSTEM CONFIGURATION

63 DATA ITEMS NOTE: Data Items on the Main Operate screen with a check box allows the number to be reset to zero. Data items are selected at the Work Configuration screen. Refer to the Work Screen Configuration section for setup instructions. The following illustrates available display parameters and their respective functions. Display parameter placement can be moved to display on the Main Operate screen to individual preferences. Refer to System Configuration for additional information on setting parameters. CLEARING ACCUMULATORS Some Data Item values can be reset to zero from the Main Operate screen. An accumulator displays (e.g., Area 1 Field, Seed Count, etc.) on the active screen and can be reset to zero by placing a check mark in the box next to the data item. Only accumulators that are on the currently-displayed screen can be reset. Accumulators are reset independently and can only be reset when the master switch is OFF. Once an accumulator has reached its maximum value, it will roll over to 0.0. Work Screen Configuration button CONTROL ACTUAL CHANNELS 1-2 NITROGN 0.0 CH1 200 LBS AC NOTE: Data Items appear on the Main Operate screen by selecting from the Work Configuration screen. Refer to the Work Screen Configuration section for setup instructions. Control Actual Channels 1-2 display the channel actual application rates in its respective units. The channel increment/decrement or preset table rate value is also displayed. When the master switch is OFF, the rate is displayed in a small font and the value displayed is the Target Rate for the channel. When the master switch is ON, the rate is displayed in a large font and the value displayed is the actual application rate. When the channel s target rate is adjusted with the Inc/Dec or rate table function, the Target Rate is displayed for 5 seconds, followed by the actual rate. This Data Item will be displayed on an entire row of the Work screen. CONTROL TARGET CHANNELS 1-2 NITROGN 0.0 CH1 200 LBS AC Control Target Channels 1-2 display the channel target set rates. The channel Inc/Dec value or preset table rate is also displayed. When the master switch is OFF, the rate is displayed in a small font. When the master switch is ON, the rate is displayed in a large font. This Data Item will be displayed on an entire row of the work screen. DATA ITEMS / 53

64 NOTE: Data Items appear on the Main Operate screen by selecting from the Work Configuration screen. Refer to the Work Screen Configuration section for setup instructions. CONTROL RATE CHANNELS N NITROGN CH1 HR Control Rate Channels 1 and 2 display the channel actual application rates. The channels calculated flow rate will display. When the master switch is OFF, the rate displays in a small font. When the master switch is ON, the rate displays in a large font. When the channel s target rate is adjusted with the inc/dec or rate table function, the target rate displays for 5 seconds followed by the actual rate. This Data Item will display on an entire row of the Work screen. CONTROL SCAN NITROGN CH2 200 LBS AC 0.0 Control Scan displays all active control channels sequentially, showing the actual rate in its respective units depending on channel setup, and the Inc/ Dec value or preset table rate for each channel in five-second intervals. This Data item displays on an entire row on the Work screen. GROUND SPEED 7.7 MPH Ground Speed displays the current ground speed of the tractor in miles per hour (Kph). The ground speed source is defined during the ground speed calibration setup. This data item also displays the implement status using an up/down arrow next to the tractor icon. TOTAL AREA Reset 0.47 AC T 0.0 LBS N 0.0 HR AC 200 LBS AC AC NOTE: Data Items on the Main Operate screen with a check box allows the number to be reset to zero. Reset box 0.00 AC T Total Area displays the area covered by the implement in acres (Ha). Total Area is calculated using the Channel Width parameter entered on the Channel Setup screen. Area accumulates when the Master Switch is ON and the ground speed is above the shutoff speed parameter entered on the Ground Speed Calibration screen. This accumulator is independent of any other area accumulator and may be reset to 0.0 at any time. Current area is retained after power down. 54 / DATA ITEMS

65 NOTE: NOTE: Data Items appear on the Main Operate screen by selecting from the Work Configuration screen. Refer to the Work Screen Configuration section for setup instructions. Data Items appear on the Main Operate screen by selecting from the Work Configuration screen. Refer to the Work Screen Configuration section for setup instructions. FIELD 1 AREA 0.00 Reset Field 1 Area displays the area covered by the implement in acres (Ha). Field 1 Area is calculated in the same manner as Total Area. This accumulator is independent of any other area accumulator and may be reset to 0.0 at any time. Current area is retained after power down. FIELD 2 AREA Reset 0.00 AC 2 Field 2 Area displays the area covered by the implement in acres (Ha). Field 2 Area is calculated in the same manner as Total Area. This accumulator is independent of any other area accumulator and may be reset to 0.0 at any time. Current area is retained after power down. CHANNELS 1-2 AREA Channels 1-2 Area displays the area covered by control channels 1 and 2. Area is calculated using the Channel Width parameter that is entered on the Control Channel setup screen. Area accumulates when the master switch is ON and the ground speed is above the Shutoff Speed parameter entered on the Ground Speed Calibration screen. This accumulator is independent of any other area accumulator and may be reset to 0.0 at any time. Current area is retained after power down. AREA SCAN AC AC 0.00 AC1 Reset Area Scan scans through all area accumulators sequentially, displaying the area for each accumulator in four-second intervals. CONTROL FEEDBACK SCAN 0.0 CH2 LBS N HR Control Feedback scans through all active control channel feedback sensors sequentially displaying the actual LBS/hr measured in four-second intervals. The current sensor is identified by the number displayed above the LBS/hr symbol. DATA ITEMS / 55

66 AREA PER HOUR 0.00 AC HR Area Per Hour displays the current area per hour in acres (Ha). The value is continuously calculated based on the current ground speed and the Channel Width parameter as entered on the Channel Setup screen. SYSTEM ACTIVE TIME Reset 0.00 HR System Active Time records the amount of time the master switch is in the ON position indicating the actual number of hours equipment has been operating. DISTANCE ACCUMULATOR Reset 0.0 FT Distance Accumular records the total number of feet traveled when the system is in automatic operation mode. CHANNEL 1-2 MATERIAL ACCUMULATOR Reset 0.0 LB 1 N Channels 1-2 Material Accumulator displays the current accumulated material according to the applied rate. CHANNEL 1-2 PRODUCT LEVEL Reset CH1 0 LB N Channels 1-2 Product Levels allows entry of how much product is in the nurse tank when full (pounds of Nitrogen). The amount of product that remains in the tank will display on the Main Operate screen when enabled. Pressing the Reset button will clear the product level and reset to the previous product level number entered. 56 / DATA ITEMS

67 AUTOMATED GUIDANCE STATUS Automated guidance can be engaged and disengaged from the Main Work screen. AB line position, cross-track error, and % of swath completion also displays. This Data Item displays on an entire row of the Work screen. 3 NOTE: Data Items appear on the Main Operate screen by selecting from the Work Configuration screen. Refer to the Work Screen Configuration section for setup instructions. NH3 TANK PRESSURE Nitrogn 1 Tank CH1 80.0PSI NH3 Tank Pressure is entered at the Main Work screen by pressing the input box. Enter in the tank pressure from the nurse tank gauge. Anhydrous density will be automatically calculated on the VT. Refer to the Density Table for the density of NH3 or Nitrogen at the operating pressure of the nurse tank. Density Table Nurse Tank Temperature Nurse Tank Pressure (PSI) Pounds per Cubic Foot NH3 Pounds per Cubic Foot Nitrogen DATA ITEMS / 57

68 BOOM STATUS Boom # Boom Status indicates the on/off status of each boom section (black-on, white-off). The boom status feature is only operational when a DICKEY-john boom switch module and boom output module are installed from boom control. This Data Item will scan through 12 sections at a time on an entire row. 58 / DATA ITEMS

69 SYSTEM OPERATION MINIMUM PRE-OPERATING REQUIREMENTS Before operating, the following items outline the minimum parameters that should be configured in the system for proper operation. Refer to appropriate sections in this manual for setup instructions. 1. Enable Implement Lift on the Ground Speed screen if a lift switch is installed. 2. Enter NH3 Tank Pressure on Main Operate screen. 3. Enter correct channel width and K-Factor. 4. Select the appropriate ground speed source. 5. Run a Ground Speed calibration. 6. Enter the maximum flow rate of the Heat Exchanger kit on Main Operate screen. 7. Enter maximum speed and maximum application rates on Control Channel Valve Calibration screen. 8. Run a Control Channel Valve calibration. 9. Enter Implement Position Coordinates for GPS, if applicable. When all parameters have been established, the system is ready for operation. When the implement is down and the master switch in the ON position, the machine is fully operational. All necessary precautions must be taken to ensure user safety. Failure to practice all necessary caution may result in serious injury or death. Use the following procedures to start operation: 1. Verify all safety equipment is in tact! 2. Lower the implement to operating position, engaging the implement switch, if enabled. 3. Start moving. 4. With the implement lowered and the tractor at its normal operating RPM, set the Master Switch to the ON position. All enabled Control Channels will begin controlling at the current ground speed. All accumulators will begin recording data. To stop operation: 1. Set the Master Switch to the OFF position or disengage the implement lift switch. All control channels will cease operation and all data accumulation will halt. 2. Operation will immediately stop when ground speed is 0. SYSTEM OPERATION / 59

70 Figure 36 Main Operate Screen Target Rate Inc/Dec % Target Rate Preset Enabled Rate 1 Accumulator OPERATE SCREEN SYMBOLS TARGET RATE The Target Application Rate displays when Master Switch is off. The actual applied rate appears during Operate mode. INCREASE/DECREASE % RATE The Increase/Decrease rate is the percentage change being applied each time the Material Increase/Decrease button is pressed during Operate mode. PRESET RATE + The Preset Rate is the applied rate that was entered at the Material Configuration setup screen and increases or decreases when the Material Increase/Decrease button is pressed during Operate mode. IMPLEMENT LIFT SWITCH When an implement lift switch is installed, the Main Operate screen will identify if the implement is in the up or down position. Using an implement lift switch automatically turns the Control Channels on and off without turning the Master Switch off. The Implement Lift Indicator must be in the Down position for the Control Channels to operate. The Implement Lift Switch box on the Ground Speed Configuration screen must be enabled if an implement lift switch is used. 60 / SYSTEM OPERATION

71 Figure 37 Implement Lift Indicators Implement Lift Indicator (Down Position-GREEN) Refer to the Implement Lift Sensor instructions for installation location. VALVE FULL OPEN Valve Full Open appears on the Main Operate screen in operate mode indicating that the valve is fully open and cannot achieve additional flow. To resolve a fully open valve, either decrease speed or decrease application rate. AUTOMATED STEERING NAVIGATION Automated Steering Navigation can be engaged and disengaged from the Main Operate screen and displays AB line position, cross-track error, % swath complete, and End of Row Alarm status. Figure 38 Automated Steering Navigation Implement Lift Indicator (Up Position-RED) 3 Press to engage and disengage TASK CONTROLLER T C The Task Controller icon appears on the Main Operate screen when Task Controller is active and controlling the application rate. Return to Task Controller to stop a task. ACCUMULATORS Some Data Item values can be reset to zero from the Main Operate screen. An accumulator displays (e.g., Area 1 Field, Seed Count, etc.) on the active screen and can be reset to zero by placing a check mark in the box next to the data item. Only accumulators on the currently-displayed screen can be reset. Accumulators are reset independently and can only be reset when the master switch is OFF. Once an accumulator has reached its maximum value, it will roll over to 0.0. (Figure 36) identifies an Accumulator icon. SYSTEM OPERATION / 61

72 APPLICATION RATE CAPACITY INDICATOR The Application Rate Capacity indicator at the bottom of the operate screen will indicate how much product is being applied in relation to tractor speed. The capacity indicator identifies the pounds per hour flow rate being applied. The higher the Flow Rate Indicator, the closer to exceeding the flow rate of the system. The maximum flow rate of the DICKEY-john Heat Exchanger kit must be entered to properly monitor the rate per (Figure 39). Figure 39 NH3 Anhydrous Ammonia Kit Maximum Flow Rate/Valve Size Application Rate (lbs of Nh 3 /hr) Single TTU 3/4 4,200 Singe TTU 1 5,500 Double TTU 1 6,800 Continental Magnum Equalizer/ SuperFlow 1 1/4 9,600 To enter a maximum flow rate: 1. Determine the type of DICKEY-john Heat Exchanger kit being used. 2. Enter the maximum flow rate lbs/hr by pressing the Maximum Flow Rate input box on the Main Operate Screen. 3. Enter the desired density constant to read product weight in NH3 or N by pressing the Density Constant input box. Figure 40 Application Rate Capacity Indicator Density Constant Input box (NH3 or N) Minimum Flow Rate of Heat Exchanger Input box to enter Maximum Flow Rate of Heat Exchanger Flow Rate Indicator 62 / SYSTEM OPERATION

73 SYSTEM INFORMATION AND DIAGNOSTICS In order to view the following information and diagnostics screens, the Master Switch must be set to the OFF position. DIAGNOSTICS Diagnostics button The Diagnostics screen provides various information from feedback sensors, valve output, and system voltages of the WSMT module. The control valve can be manually opened on this screen when necessary. Refer to VALVE CALIBRATION for additional information. Each channel has its own Diagnostics screen. None of the items on the screen may be edited. However the Channel Pulse Count data can be reset. The system may be active while the Diagnostic screen is displayed. Press the Diagnostics button to access the Diagnostics screen. Figure 41 Diagnostics Screen CHANNEL #1 Nitrogn 1 LB PER HR Nitrogn 1 Nitrogn 1 CH SETPOINT The Channel Setpoint value is calculated by the system. It displays the calculated feedback frequency of the application rate sensor or flowmeter used for that channel s feedback. CH TARGET The Channel Target value is the current channel s rate as entered into the Target Rate constant on the Channel Configuration screen. CH ACTUAL RATE The Channel Actual Rate value is the current channel s actual controlled rate with the system active. The Channel Target value is the current channel s rate as entered into the Target Rate constant on the Channel Configuration screen. SYSTEM OPERATION / 63

74 NOTE: NOTE: In some instances, FREQ REL GSPD and FREQ DIG GSPD read the same values simultaneously depending upon the sensor used. This is normal and does not impact operation. If the values are reversed and the value displays a 1 when the implement is raised, the wiring for the implement switch will need to be reversed so that an accurate readout is achieved. CH LBS PER HOUR Indicates the number of pounds of N being dispensed per hour by channel. CH PWM The Channel PWM value is the current pulse width modulation (PWM) output drive signal to the Servo valve. CH PULSE COUNT The Channel Pulse Count value is the accumulated pulse count detected from the channel feedback sensor. This value may be reset by pressing the Reset Channel Pulse Count button. CH FREQ FILT The Channel Frequency s Filtered value is the filtered frequency output from the channel feedback sensor. FREQ REL GSPD The Frequency Reluctance Ground Speed value is the reluctance sensor output signal in hertz (hz). This value is present when ground speed is provided by a reluctance sensor connected to the actuator harness. FREQ DIG GSPD The Frequency Digital Ground Speed value is the digital sensor output signal in hertz (hz). This value is present when ground speed is provided by a radar sensor or other digital speed sensor connected to the actuator harness. FREQ PRESS 1 The Frequency Pressure value is the output frequency signal of the air pressure sensor in hertz (hz). This value will typically fall between 200 hz and 1100 hz. VALVE FULL OPEN The Valve Full Open value indicates that the maximum flow rate has been achieved based on the calculated rate (maximum application x maximum speed x channel width) entered at the Valve Calibration screen. IO IMP LIFT The IO Implement Lift value displays the current state of the implement status switch. This value will be 0 when the implement is down. The value will be 1 when the implement is raised. APP ID Hardware identification only. Not applicable to the end user. 64 / SYSTEM OPERATION

75 SOL PWR VOLT The Solenoid Power Volt value displays the detected solenoid power voltage. This voltage level is the high current voltage leg of the system which is used to power high current solenoids and valve actuators. This value will generally be equal or nearly equal to the tractor battery voltage. ECU PWR VOLT The Electrical Control Unit (ECU) Power Volt value is the detected ECU voltage. This voltage level is the low current voltage leg of the system and is used to power modules and sensors. This value will generally be equal or nearly equal to the tractor battery voltage. SNSR PWR VOLT The Sensor Power Volt value is the detected output voltage to the seed sensor on the Working Set Master (WSMT) module. This value is typically +8 VDC. GND VOLT If the system is properly grounded, this value is typically 0.0. SYSTEM OPERATION / 65

76 ACCUMULATORS/DISTANCE SCREEN Accumulators button The Accumulators/Distance screen displays the amount of time the system has been on, the amount of time and area application control has occurred, and the distance traveled. Data on this screen is for display purposes only and cannot be edited. Press the Accumulators button to access the Accumulators/Distance screen. Figure 42 Accumulators/Distance Screen NOTE: The Master Switch must be set to the OFF position to display the Accumulators/Distance screen. POWERED ON TIME Powered On Time is the accumulated time, in hours, that the system has been powered ON. Powered On Time accumulates regardless of the mode of operation - whether it is in SETUP/CONFIGURATION mode or OPERATE mode. Powered On Time cannot be reset. SYS. ACTIVE TIME System Active Time is the accumulated time, in hours, that the machine has actively been controlling. System Active Time accumulates whenever the implement is lowered, the Master Switch is ON, and ground speed is greater than zero. System Active Time can be reset. SYS. ACTIVE AREA System Active Area is the accumulated area that the machine has actively covered. System Active Area accumulates whenever the implement is lowered, the Master Switch is ON, and ground speed is greater than zero. System Active Area canot be reset. 66 / SYSTEM OPERATION

77 Start Distance Accumulator button Stop Distance Accumulator button DISTANCE Distance is the accumulated distance, in feet (meters) that the implement has travelled. The Distance accumulator function can be controlled by using the following procedures: 1. Press the Start Distance Accumulator button to begin accumulating distance. This occurs whenever there is forward ground speed. 2. Press the Stop Distance Accumulator button to stop distance accumulation. 3. Press the Reset Distance Accumulator button to reset the value back to 0.0. Reset Distance Accumulator button SYSTEM OPERATION / 67

78 INFORMATION SCREEN Information button The Information screen displays the system software versions and is typically used for troubleshooting. No information on the screen can be edited. Press the Information button to access the Information screen. Figure 43 Information Screen Module Position Module Type Serial Number RESETTING NOVRAM VALUES NOVRAM Reset button NOVRAM refers to the memory location of the Working Set Master (WSMT) module where all configuration and setup data for the system are stored. Resetting the NOVRAM will reset all data to factory default constants. 1. Press the NOVRAM Reset button to access the Novram Reset Confirmation screen. 2. Press the Reset Novram button to reset to factory standard defaults. 3. Press the Diagnostics button to return to the Diagnostics screen. Diagnostics button DO NOT press the NOVRAM Reset button unless you want ALL system data settings to be reset to factory standard defaults. It is recommended that NOVRAM not be reset unless instructed by DICKEY-john Technical Support. 68 / SYSTEM OPERATION

79 Figure 44 Reset Novram Screen ACKNOWLEDGING ALARM CONDITIONS Alarm Cancel button i Alarm Information button Alarm Log button Various alarm conditions may be presented to the operator whenever the system encounters an abnormal condition or detects a specific alarm. Alarms are typically in a full screen display describing the alarm and, dependent upon the alarm type, may give the operator instructions on how to fix the alarm. Each alarm type has an associated alarm number, which can be cross-referenced in the TROUBLESHOOTING AND ALARMS section. Some alarms (such as the Master Switch alarm) require a specific action by the operator before the alarm condition will cease. In these cases, instructions are indicated on the alarm display. Other alarms can be acknowledged by pressing the Alarm Cancel button of ESC key. Detailed information about the alarm can be accessed by pressing the Alarm Information button. ALARM HISTORY The Alarm Log screen provides a list of specific alarms that have been issued during system operation. Information displayed on the Alarm Log screen is informational only and cannot be edited. Each time a specific alarm condition is detected, it is logged and communicated to the WSMT. To view Alarm History: 1. Press the Alarm Log button to access the Alarm Log screen. The number of the alarm, along with the alarm description displays. Up to 20 alarms may be recalled. Each alarm occurrence can have up to 5 instances of the alarm tagged with a date and time stamp. SYSTEM OPERATION / 69

80 Alarm Up/Down button 2. To select specific Alarm details, press the Alarm Up or Alarm Down buttons to move the small display arrow next to the desired alarm number. 3. Press the Alarm Log Detail button to view all of the occurrences of the selected alarm. The down arrow in the lower right corner signifies that more alarms are present and accessible by pressing the Alarm Up or Alarm Down buttons. Figure 45 Alarm Log Screen Alarm Log Detail button ALARM LOG DETAIL 1. To view specific alarm details, press the Alarm Log Detail button. The time and date of the selected alarm displays for each occurred instance. The Alarm Log will save up to 5 instances of the selected alarm. 70 / SYSTEM OPERATION

81 Figure 46 Alarm Log Detail Screen Reset Alarm Log button RESET ALARM LOG To reset the Alarm Log, press the Reset Alarm Log button. 1. Press YES button to clear. 2. Press NO button to return to Alarm Log Detail screen. Figure 47 Reset Alarm Log Screen SYSTEM OPERATION / 71

82 72 / SYSTEM OPERATION

83 TASK CONTROLLER The following section is specific to IntelliAg systems operating with Task Controller functionality. Systems with no file server or task controller capability will not have the below features. CONFIGURING IMPLEMENT OFFSET (GPS) IntelliAg button Control Channel button Implement Offset button Task Controller functionality requires that implement coordinates are established in relation to the GPS antenna location on the tractor and is saved to the WSMT. Therefore, when an implement is connected to a tractor, the correct coordinates will appear on the VT. Implement coordinates should be determined by where the product is applied, not from the location it is stored, and in relation to: Antenna distance from the rear hitch connection Antenna distance from the center of each channel to the hitch connection. IMPORTANT: Position of coordinates to the hitch will determine if the number is entered as positive (+) or negative (-). To enter an Implement Offset: 1. Press the IntelliAg button on the left side of the VT screen. 2. Press the Control Channel button. 3. Press the Implement Offset button to display the Implement Offset screen. Figure 48 Implement Offset screen TASK CONTROLLER / 73

84 APPLICATION RATE CONTROLLED BEHIND TRACTOR A distance from the implement bar to the hitch to be entered as a (-x) negative entry. A distance from the center of channel to hitch connection to be entered as: Channels to the left of the hitch (negative entry) (-y) Channels to the right of the hitch (positive entry) (+y) APPLICATION RATE CONTROLLED IN TRACTOR FRONT A distance from the controlled rate to the hitch to be entered as a (+x) positive entry. A distance from the center of channel to hitch connection to be entered as: Channels to the left of the hitch (negative entry) (-y) Channels to the right of the hitch (positive entry) (+y) RELOAD APPLICATION RATES Reload button Reload resets a system that has been running a task under Task Controller map control. An SD Card graphic icon on the IntelliAg Work screen indicates this condition. The Reload button appears on the IntelliAg Work screen to select current rates or to reload IntelliAg rates. The Reload button only appears if a task is stopped in Task Controller and: ground speed is greater than 0 the master switch is ON for 5 seconds the implement lift switch is down (operate mode) An alarm will occur within a 5-second period: Press the Current button to continue to run a task under Task Controller map control Press the Reload button to reset the system to IntelliAg rates Figure 49 Reload screen 74 / TASK CONTROLLER

85 IMPORT/EXPORT DATA Import/Export button Implement configurations stored on the Working Set Master (WSMT) can be exported to an SD card for transfer to other machines. This file transfer eliminates manual entry of settings to similar machines. Only implement configurations created from the Virtual Terminal can be imported and exported; no configurations created from a PC will transfer. IMPORTANT: Import/export does NOT save ECU or other Task Controller functions. To transfer WSMT configurations: 1. Verify that the SD card is inserted into the VT and that all system electronics are connected, configured, and calibrated properly. 2. From the IntelliAg Main Operate screen, press the Next page button to scroll to the Import/Export button. Export button Import button EXPORT DATA 1. Press the Export Data input box and enter a file name. 2. The new Data file name will appear in the input box and be saved as an.xml file extension. 3. Press the Export button. As files are saved an hour glass will flash at the top of the screen and Exporting Data... will appear at screen bottom. A successful data transfer will appear when complete. 4. The Import button will appear after a successful transfer. NOTE: The file name is case sensitive and must be entered exactly for the import function to read the file. Figure 50 Export Data screen TASK CONTROLLER / 75

86 Power button IMPORT DATA 1. Insert SD card into another Virtual Terminal. 2. At the Import/Export Data screen enter the Import File name to transfer. 3. Press the Import button. As files are transferring, an hour glass will flash and Import Data Validation will appear at screen bottom. 4. Press the Power button to reboot the IntelliAg WSMT. Figure 51 Import Data Validation Screen 76 / TASK CONTROLLER

87 TROUBLESHOOTING & ALARMS Alarm Cancel button i Alarm Information button Alarms are indicated on the Virtual Terminal with the following graphic, as well as with a continuous, audible alarm. The audible alarm is terminated by pressing the Alarm Cancel button or ESC key. In addition, detailed descriptions of the current alarm can be viewed by pressing the Alarm Information button. Some of the alarm conditions display instructions on correcting the situation. IntelliAG 212 Alarms are presented in a full screen display that will describe the alarm and, depending upon the alarm, may give instructions on how to fix the alarm. Each alarm type has an associated alarm number that can be cross-referenced in this section. Some alarms (for instance a Master Switch alarm) will require a specific action before the alarm condition will cease. In these cases, the instructions to proceed are indicated in the alarm display. The following table describes the possible alarm conditions, causes, and remedies. TROUBLESHOOTING & ALARMS / 77

88 78 / TROUBLESHOOTING & ALARMS

89 ALARM # ALARM PROBABLE CAUSE CORRECTIVE ACTION 1 Software Task Stack Overflow Alarm 1. Internal system software error. 1. Cycle system power OFF/ON. If condition persists, contact DICKEY-john Technical Support ( ) or DICKEY-john Europe ( ). 2 Software System Stack Overflow Alarm 1. Internal system software error. 1. Cycle system power OFF/ON. If condition persists, contact DICKEY-john Technical Support ( ) or DICKEY-john Europe ( ). 3 VT Out of Memory Alarm THE ECU MEMORY REQUIREMENTS ARE GREATER THAN THE VIRTUAL TERMINAL CAN HANDLE. 200 Master Switch Timeout Alarm 201 Master Switch Assignment Alarm 205 Control Channel Failure Alarm 206 Control Channel Unable to Control Alarm 207 Control Channel Unstable Alarm 209 Control Channel High Limit Exceeded Alarm 1. Master Switch ON at power up. 2. Master Switch ON after leaving a setup screen. 3. Shorted or damaged tractor harness. 4. Defective Master Switch. 1. External Master Switch is not assigned to the Auxiliary Input. 1. Defective control valve. 2. Defective feedback sensor. 3. Defective module harness or module harness fuse. 4. Defective module. 1. Incorrect control channel settings. 2. Incorrect feedback sensor installation. 3. Defective feedback sensor. 1. Incorrect control channel settings. 2. Incorrect feedback sensor installation. 3. Defective feedback sensor. CONTROL LIMITED BY HIGH LIMIT. UNDER APPLICATION IS OCCURRING. NOTE: System will not run faster than High Limit Value. 1. Remove any unnecessary ECU s 2. Contact DICKEY-john Technical Support ( ) or DICKEY-john Europe ( ) for updated hardware. 1. Move Master Switch to the OFF position 2. Move Master Switch to the OFF position. 3. Check for damage on the tractor harness at the master Switch connector. 4. Inspect Master Switch for damage or replace. 1. Assign Master Switch to the Auxiliary Input. Refer to Auxiliary Input/Function Assignment. 2. Decline use of Auxiliary Input Switch. 1. Inspect control valve for damage or replace. 2. Inspect feedback sensor for damage or replace. 3. Inspect module harness for damage. Replace harness fuse. 4. Inspect module for damage or replace. 1. Verify correct setup constants on the Channel Configuration screen. Perform a valve calibration. 2. Verify correct installation of the feedback sensor. 3. Inspect feedback sensor for damage or replace. 1. Verify correct setup constants on the Channel Configuration screen. Perform a valve calibration. 2. Verify correct installation of the feedback sensor. 3. Inspect feedback sensor for damage or replace. 1. Check and/or reduce speed. 2. Verify Control Channel setup (high RPM) 3. Perform new valve calibration. 4. Check and/or reduce target rate. 5. Inspect feedback sensor for damage. 6. Inspect control valve for damage. 7. Inspect harness/module for damage. 8. Decrease target rate. TROUBLESHOOTING & ALARMS / 79

90 ALARM # ALARM PROBABLE CAUSE CORRECTIVE ACTION 221 Control Channel Invalid State Alarm 222 Control Channel Setup Height Error Alarm 224 No Control Channel Gain Steps Calculated Alarm 1. Internal system software error. 1. Cycle system power Off/On. If condition persists, contact DICKEY-john Technical Support ( ) or DICKEY-john Europe ( ). 1. Implement hydraulic system malfunction. 2. Defective control valve. 3. Incorrect feedback sensor installation. 4. Defective feedback sensor. 5. Limit Max Output set too low. 1. Implement hydraulic system malfunction. 2. Defective control valve. 3. Incorrect feedback sensor installation. 4. Defective feedback sensor. 237 Product Level Low Alarm 1. Calculated product level has dropped below alarm level. 246 Master Switch button Press Alarm Warning of action associated with keypress. 252 Master Switch OFF Alarm 1. Conditions indicate that the master switch is off and should be on (ground speed >0 and implement down) 604 ECU Voltage Out of Range Alarm 605 Solenoid Voltage Out of Range Alarm 606 Ground Offset Voltage Out of Range Alarm ECU VOLTAGE IS BELOW 11V OR HIGHER THAN 16V. 1. Damaged CAN or module harness. 2. Defective module SOLENOID VOLTAGE IS BELOW 11V OR HIGHER THAN 16V. 1. Damaged CAN or module harness. 2. Blown module harness fuse. 3. Defective module. 1. Damaged/shorted Actuator Harness. 2. Defective PWM valve driver or Servo valve driver. 3. Defective module. 1. Verify implement hydraulic system operation. 2. Inspect control valve for damage. Replace if necessary. 3. Verify correct installation of the feedback sensor. 4. Inspect feedback sensor for damage or replace. 5. Set Limit Max Output to a higher PWM% on the Valve Calibration screen. Perform a new valve calibration. 1. Verify implement hydraulic system operation. 2. Inspect control valve for damage. Replace if necessary. 3. Verify correct installation of the feedback sensor. 4. Inspect feedback sensor for damage or replace. 1. Fill product bin and reset level. 1. Press Control Start key to activate control. 1. Press the Master Switch ON button or turn the master switch on to activate control. 1. Inspect CAN/module harness of the identified module for damage. 2. Inspect identified module for damage or replace. 1. Inspect CAN/module harness of the identified module for damage. Repair or replace harness. 2. Inspect module harness fuse or replace. 3. Inspect identified module for damage or replace. 1. Inspect Actuator Harness for damage around the Servo valve connections. Repair or replace harness. 2. Inspect Servo valve drivers for damage and replace if necessary. 3. Inspect identified module for damage and replace if necessary. 80 / TROUBLESHOOTING & ALARMS

91 APPENDIX A SYSTEM CAPACITY CONSIDERATIONS The Continental Magnum Equalizer NH3 Heat Exchanger System/Kit (DICKEY-john Super Flow Assembly) system allows for faster runs at lower tank pressures. The system can attain flow rates up to 9,600 lbs/hr. It contains standard 1 1/4 inch plumbing and is compatible with the N-Serve nitrogen stabilizer. It features interchangeable orificed hose barbs for constant 2% or less vapor bleed off. To ensure the highest possible flow rates, your applicator plumbing must be sized properly. The following is a guideline for transfer of NH 3 from the nurse tank to the applicator. NH 3 SYSTEM FLOW RATES Lbs/Hour Plumbing Size 0-3,600 1 inch feed line and breakaway 3,600-6, /4 inch feed line and breakaway 6,800 and up 1 1/2 inch feel line and breakaway All maximum flow rates listed are at 110 psi tank pressure. To account for application in cold conditions where tank pressures will be significantly lower, use the following conversion when sizing an NH 3 system. Approximately 1/3 of the total system capacity is lost at one half of the tank pressure. Example: 42.5 ft x 6 mph x 200 lbs. NH 3 x = 6181 lbs/hr 6181 lbs/hr x = 8251 lbs/hr OPERATING PRINCIPLES OF ANHYDROUS AMMONIA Based on the calculation above, you would need a system with at least 8251 lbs/hr capacity to put on the required amount at 55 psi tank pressure or in this instance, a DICKEY-john Super Flow kit rated at 9600 lbs/hr maximum flow rate. The flow-based control system will accurately control the application of NH 3 as long as liquid NH 3 is flowing through the flowmeter. As illustrated in (Figure 44), vapor bubbles are formed in the liquid as it leaves the nurse tank. This vaporization occurs as a result of the pressure loss required to push liquid NH3 out of the nurse tank. Furthermore, any pressure losses between the tank and the flow metering point can only generate more vapor. The Super Flow, inserted just before the flowmeter, transfers heat from the warmer incoming liquid-vapor mix to the cooler outgoing liquid-vapor mix. This heat transfer allows incoming vapor to cool and condense into liquid, thus providing a pure liquid flow to be metered APPENDIX A / 73

92 Figure 44 Anhydrous Ammonia Applicator Super Flow Assembly 1 1/4 x 4 Nipple * 1 1/4 to 1 Elbow/Vapor Discharge Adaptor 1 1/4 Ball Valve Control Existing Regulator Recommended Shutoff Valve (not supplied by DICKEY-john) ESSURE UGE TANK SHUTOFF VALVE SHUTOFF VALVE TANK QUICK CONNECT COUPLING Hose Barb Recommended Shutoff Valve (not supplied by DICKEY-john) Y Strainer Actuator Mounting Bracket Pressure Gauge Tool Bar Manifold EXCESS FLOW VALVE BREAK-AWAY CONNECTOR Pressure Relief *Base Elbow Bleeder Valve Flowmeter 1 1/4 Inch Elbow Knife Base Mounting Plate In practice, doubling the flowrate will increase the volume of vapor generated by factors of 4 to 8 times. This means 4 to 8 times more thermal capacity is needed from the Super Flow. In terms of cost and size, this is not an overly desirable solution. It is far more cost effective to minimize the generation of vapor before the material reaches the Superflow and flowmeter. The following recommendations address this issue. Recommendations: 1. Use 1 1/4 inch or larger hoses, pipe fittings, and valves between the nurse tank and the Super Flow. 2. Do not coil up excess supply hoses; use only the lengths required. 3. Use 1 1/4 inch or larger breakaway couplers. 4. Do not use elbows if a straight coupler can be used. 5. Keep any filter screens in the system cleaned. 6. Provide adequately sized downstream plumbing to prevent excessive manifold pressure. IMPORTANT: Manifolds typically require 10 psi or greater to provide uniform distribution. 7. If an old flow regulator is left in the system, be certain that it is full open. 8. Do not expect all nurse tanks to work equally. 9. Keep knife injector tubes from plugging. 10. Replace collapsed, soft, or kinked hoses. 11. When two nurse tanks are used, tee the feed hoses together just before the Super Flow. 74 / APPENDIX A

93 Use a 1 1/4 inch breakaway coupler for each feed hose. 12. Nurse tanks with temperatures above air temperature will provide greater flowrates than those with temperatures below air temperature. CHARACTERISTICS OF ANHYDROUS AMMONIA Under normal atmospheric conditions, anhydrous ammonia is a gas. It is lighter than air, colorless*, and has a characteristic sharp odor. The chemical formula for ammonia is NH 3, which means that in every molecule of ammonia, there are three hydrogen atoms for each nitrogen atom. Since a nitrogen atom is 14 times heavier than a hydrogen atom, ammonia contains 82% nitrogen by weight. The pressure required to liquify ammonia gas varies with temperature (boiling point). The density of liquid ammonia also varies a a function of temperature. Some of this information is illustrated in the following table. NURSE TANK NURSE TANK POUNDS PER CUBIC POUNDS PER CUBIC O TEMPERATURE F PRESSURE (PSI) FOOT NH3 FOOT NITROGEN *The white cloud seen when liquid ammonia is released into the atmosphere is actually water condensed from the air APPENDIX A / 75

94 SYSTEM CONFIGURATION WORKSHEET Channel Configuration 1 2 Channel Configuration 1 2 Type Type Preset Method Disabled Disabled Preset Method Enabled Enabled Target Rate Rate 1 Max Rate Rate 2 Min Rate Rate 3 Inc/Dec % Rate 4 Control Mode Rate 5 Drive Type Rate 6 Drvive Freq Rate 7 Input Filter Rate 8 K-Factor Rate 9 Channel Width Rate 10 Product Level Alarm Control Mode Drive Type Drvive Freq Input Filter K-Factor Channel Width Product Level Alarm Ground Speed Configuration Source Manual Speed Ground Speed Constant Shutoff Speed Minimum Override Master Sw Timeout Grouind Speed Fail Alarm Delay Implement Lift 76 / APPENDIX A

95 WORK SCREEN CONFIGURATION Work Screen 1 Large Bargraphs Work Screen 2 Work Screen APPENDIX A / 77

96 78 / APPENDIX A

97 Dealers have the responsibility of calling to the attention of their customers the following warranty prior to acceptance of an order from their customer for any DICKEY-john product. DICKEY-john WARRANTY DICKEY-john warrants to the original purchaser for use that, if any part of the product proves to be defective in material or workmanship within one year from date of original installation, and is returned to DICKEY-john within 30 days after such defect is discovered, DICKEY-john will (at our option) either replace or repair said part. This warranty does not apply to damage resulting from misuse, neglect, accident, or improper installation or maintenance; any expenses or liability for repairs made by outside parties without DICKEY-john s written consent; damage to any associated equipment; or lost profits or special damages. Said part will not be considered defective if it substantially fulfills the performance expectations. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF MERCHANTABILITY, FITNESS FOR PURPOSE, AND OF ANY OTHER TYPE, WHETHER EXPRESS OR IMPLIED. DICKEY-john neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said part and will not be liable for consequential damages. Purchaser accepts these terms and warranty limitations unless the product is returned within fifteen days for full refund of purchase price. For DICKEY- john Service Department, call in either the U.S.A. or Canada Headquarters: 5200 Dickey-john Road, Auburn, IL USA TEL: , FAX: , WEB: Europe: DICKEY-john Europe S.A.S, 165, boulevard de Valmy, Colombes France TEL: 33 (0) , FAX: 33 (0) WEB: Copyright 2009 DICKEY-john Corporation Specifications subject to change without notice.