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HARDI

®

MUSTANG 3500 OPERATOR’S MANUAL

7.0 CALIBRATION

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

A Software Utility package is provided with each system. If you have
access to a PC with CD drive, this software can be easily loaded onto a
PC or Pocket PC. The Utility Software includes a calibration “wizard”
that directs the operator through the MUSTANG calibration process and
automatically sets up calibration for various types of systems. If the PC
is connected to the MUSTANG, the calibration parameters can be
downloaded directly to the MUSTANG, or the calibration settings can be
printed out and entered into the MUSTANG manually. The Utility
Software also provides the ability to reprogram the MUSTANG with
program upgrade files provided by HARDI

®

via e-mail (or on floppy disk).

See the Compact Disc you received with your MUSTANG Automatic
Rate Controller.

A 9-pin RS-232 cable is used to connect the HARDI

®

MUSTANG 3500

to a PC, not Null Modem. The HARDI

®

MUSTANG 3500 must also be

connected to a 12-volt DC power source in order to communicate with
the PC.

We’ll begin with the System Calibration section.

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Summary of Contents for MUSTANG 3500

Page 1: ...HARDI MUSTANG 3500 Operator s Manual 67301603 6 04 ...

Page 2: ......

Page 3: ...Hardi reserves the right to make changes in design material or specification without notice thereof HARDI MUSTANG 3500 Operator s Manual Hardi P N 67301603 6 04 HARDI SPRAYERS ...

Page 4: ...3 Installing Pressure Transducer 24 Twin Force Installation Fan RPM and Slot Angle Adjust 25 26 7 0 Calibration 27 Entering System Calibration 28 Units Filter 29 Entering Standard Calibration 34 Target Rate Pressure Sensor Zeroing 35 Calibration Values 41 Loading Factory Defaults 42 Pre field System Checkout 43 8 0 Troubleshooting 46 Checking Individual Components 48 Appendices Appendix A Fine tun...

Page 5: ...TANG 3500 Automatic Rate Controller You will find many helpful hints as well as important safety and operation information Some of the features on your HARDI MUSTANG 3500 Automatic Rate Controller were suggested by other HARDI owners There is no substitute for on farm experience and we invite your comments and suggestions Please address your correspondence to the Service Manager at one of these br...

Page 6: ...INDEPENDENT RATE SETTINGS The system provides three application rate settings with clearly marked buttons to choose the desired rate The three rates can be set up in two ways If the same nozzles are always used three selectable rates can be set up for varying field conditions If three different sets of quick change nozzles are used each of the three rates can be set up for a different set of nozzl...

Page 7: ... can be printed directly from the RS 232 output to the printer SOFTWARE UTILITIES A compact disc with Utility Software is provided with each system If you have access to a PC with CD drive this software can be easily loaded on the PC or pocket PC The Utility Software includes a calibration wizard that directs the operator through the MUSTANG calibration process and automatically sets up calibratio...

Page 8: ...injury Follow recommended precautions and safe operating practices PTO driven machinery can cause serious injury Before working on or near the PTO shaft or servicing or cleaning the driven machine put the PTO lever in the DISENGAGE position and STOP the engine WARNING Disconnect all electronic components from power supply before welding on sprayer Do not use high pressure cleaner directly on elect...

Page 9: ...Cable Sprayer Control Module Operator s Manual Optional Remote Run Hold Cable and Foot Switch 3 wire Optional Remote run hold cable With standard set up included are 2 3 wire adapter cables and 1 2 wire adapter cable With twin force set up included are 3 2 wire adapter cables and 3 3 wire adapter cables 2 wire Mounting kit for console Utilities CD 3 0 COMPONENT PARTS AND ASSEMBLY HARDWARE Before b...

Page 10: ...ANUAL 1 4a 4 4b 5 6 7 7a 7b 8 9 10 11 12 14 13 15 16 3 2 4 0 CONSOLE FUNCTIONS This section gives a brief explanation of each button switch and rotary switch position and will help to familiarize you with the console and its operation ...

Page 11: ... Field Area keeps a running count of field area Field Flow keeps a running count of field flow CALIBRATION Target Rate target application rate GPA LPH Min Flow minimum gallons liters per minute Adjust Rate on the go adjustments to target rate when operating in AUTO mode Flow Cal flow meter calibration value PPU Boom Width enter the working width for each of your boom sections Speed Cal Distance en...

Page 12: ...rate TEST button used to enter test speed mode ADJUST switch used to adjust various settings or rates TANK button displays the amount of material remaining in tank PRINT button allows user to print field counter data BOOM switches on off control for each boom section RATE buttons selects a preset target application rate for each button 10 11 12 13 14 15 16 ...

Page 13: ...the vehicle s electrical system 1 Fig 5 1 Upon start up the console will briefly approximately three seconds display the software versions that are programmed into the console and sprayer control module Start up of the HARDI MUSTANG 3500 Upper half displays console main program version flash 1 Lower left displays Spray Control Module program version flash 3 Lower right displays console display pro...

Page 14: ...lay For example in the figure below the upper display tells the operator that the actual target RATE 1 is 20 0 GPA The lower left display tells the operator that their pressure is at 56 PSI and the lower right display tells the operator that their speed is currently 5 8 MPH if the rotary switch is set to speed SYSTEM CAL BUTTON To enter system calibration toggle the Master switch to HOLD and turn ...

Page 15: ...unces per minute liters per minute TOTAL AREA Displays the area covered since the counter was last reset to zero This counter does not accumulate area when the console is in HOLD or if all boom section switches are turned off If this counter is reset TOTAL FLOW will reset as well FIELD AREA Displays the area covered since the counter was last reset to zero This counter does not accumulate area whe...

Page 16: ...n the center AUTO position on start up the marker is set to start distributing foam on the left side When in AUTO marker side changes automatically when the operator transitions the master switch from AUTO to HOLD or MAN to HOLD Foam marker will NOT turn on if the Master switch is in HOLD or if the console is in rHold MARKER ON OFF BUTTON To activate the Foam Marker in AUTO mode press the Marker O...

Page 17: ... stop accumulating and foam marker will stop For example when turning on end rows place the MASTER switch in HOLD RESET BUTTON The RESET button is used to clear a selected counter To do this simply turn the rotary dial to any of the counter positions Total Area Field Area Total Flow Field Flow or Distance and press and hold the reset button for one second IMPORTANT when clearing field area field f...

Page 18: ...SWITCH to the ANGLE position and the ROTARY SWITCH to any green position the lower right area of the display must read PrSET If the RATE 1 2 or 3 button is pressed the Slot Angle will transition to the associated preset value The value in lower left display represents the time in seconds the Slot Angle actuators will run from the zero point If the value in RATE 1 is set to 2 5 and the Rate 1 butto...

Page 19: ...on TEST BUTTON The TEST button is used to enter the Test Speed mode when calibrating the system Refer to Pre field System Checkout for more information on Test Speed and using the TEST button ADJUST SWITCH The ADJUST switch serves many functions within the system and can be used within Calibration and Operation AUTO and MAN During normal operation when the master switch is in automatic AUTO and th...

Page 20: ...d off the respective width is subtracted from the total width to accumulate area based on the new active application width If a boom section switch is turned on its respective section valve should be on If a boom section switch is turned off its respective section valve should be off No valves should be on if the console is in HOLD or in AUTO while speed is zero RATE BUTTONS The RATE buttons serve...

Page 21: ...verview of the HARDI MUSTANG 3500 NOT for Twin Force RS 232 Remote Run Hold Radar Input Console Cable System Power Cable Hitch Connector Extension Cable Power Foamer Pressure Natural Tie Speed Yellow Tie HARDI Sprayer 20 pin Connector Flow Green Tie ...

Page 22: ...0 for Twin Force operation RS 232 Remote Run Hold Radar Input Console Cable Hitch Connector System Power Cable Extension Cable Power Foamer Pressure Natural Tie Speed Yellow Tie Flow Green Tie RPM Adjust Blue Tie Slot Angle Adjust Grey Tie RPM Red Tie HARDI Sprayer 20 pin Connector ...

Page 23: ...ion mark holes drill 1 4 7mm holes and mount bracket with bolts lockwashers and nuts provided If bolts are not practical use self tapping screws See Figure 7 1 A chassis ground wire is provided to reduce electrical interference This wire is connected to the male terminal on the back of the console and then to a good chassis ground point Place the console in the U bracket and install the console kn...

Page 24: ...e Figure 7 3 Route the power cable from the battery to the back of the tow vehicle In routing cable to battery avoid areas where the cable may be subjected to abrasion or excessive heat Connect the ORANGE wire hot to the positive battery terminal Your HARDI MUSTANG 3500 is equipped with an electronic memo ry which does not require a constant supply of power to retain daily totals or calibration va...

Page 25: ...l Module Mate the wires as shown below Be sure to slide a piece of heat shrink tubing over each individual wire before mating Then shrink tubing by applying heat evenly along tube Plug the adapter cable into Sprayer Control Module speed input pigtail with Yellow Cable Tie DUPLICATE THIS FOR FLOW AND RPM SENSOR INTERFACE Blue Red Black White Brown Black Speed Flow or RPM Sensor 3 wire adapter cable...

Page 26: ...ection for transducer BROWN 12V supply BLACK Ground BLUE Signal RPM SENSOR CABLE WIRE COLOR CODE Wire color Connection for transducer BROWN 12V supply BLACK Ground BLUE Signal FLOW TRANSDUCER CABLE WIRE COLOR CODE Wire color Connection for transducer BROWN 12V supply BLACK Ground BLUE Signal Note Route the cables from the module to the sensor location hiding all excessive cable under the sprayer f...

Page 27: ... onto the tee Route the cables back to the HARDI Sprayer Control Module and plug the two wires into the appropriate terminals ADAPTER CABLE COLOR CODE Wire color DESCRIPTION RED 12V supply BLACK Signal PRESSURE TRANSDUCER COLOR CODE Wire color DESCRIPTION BROWN 12V supply BLUE Signal Route the Pressure Transducer Cable to the HARDI Sprayer Control Module Mate the wires as shown below Be sure to sl...

Page 28: ...cables at the fling lead end with colored ties provided Blue tie for RPM and gray tie for slot angle At the electric over hydraulic control box insert both adapter cables into hydraulic control box through separate spare rubber gromets at the bottom of hydraulic control box Be sure to strain relief similar to other incoming cables Pull the brown and blue wires at V7 from the board slot angle adjus...

Page 29: ...t V8 Test for correct operation of slot angle adjust and RPM adjust before sealing heat shrink Shrink tubing by applying heat evenly along length of tubing Replace cover on hydraulic box Electric over hydraulic junction box for twin force located on inside of twin force center section ...

Page 30: ...ss and automatically sets up calibration for various types of systems If the PC is connected to the MUSTANG the calibration parameters can be downloaded directly to the MUSTANG or the calibration settings can be printed out and entered into the MUSTANG manually The Utility Software also provides the ability to reprogram the MUSTANG with program upgrade files provided by HARDI via e mail or on flop...

Page 31: ...hanges you need to enter System Calibration To enter System Calibration 1 Turn the power switch OFF 2 Place the AUTO MAN HOLD switch in the HOLD position 3 Place the Rotary switch in the SPEED position 4 While pressing the SYSTEM CAL button turn the power switch ON NOTE The console will display SYS SYSTEM and Cal in the upper display window The warning light will flash See Figure 8 1 Exiting Syste...

Page 32: ...e system EnG American English mEt Standard metric Dial position Display will read TARGET RATE PSI CAL bar data meters inches Rate ERROR 1 2 3 Gal Ac kg ha Lbs N Ac liters ha Gal 1000 data meters inches ENGLISH METRIC AREA Acres Hectares VOLUME Gallons Liters SPEED Miles Hr Kilometers Hr DISTANCE Feet Meters PRESSURE Pounds Sq In Bar FLOW PER MINUTE Gallons Min Liters Min SPRAY RATE Gallons Acre Li...

Page 33: ...n A Flow for the entire boom Flow Per Boom When TIPS 0 Gallons per minute Liters per minute is displayed for the entire boom B Flow for individual sprayer tip Flow Per Nozzle When set to a nonzero value TIPS typically 24 73 depending on boom size MAX ounces 6553 5 per minute NOTE It is very important to ensure that the total number of spray tips is entered or else the Flow Per Nozzle rate will be ...

Page 34: ...of the pressure regulation valve The default setting POS should correct for most installations Regulation Constant Default setting 2 This SYSTEM CAL position is used to make adjustment to how aggressive the regulation valve is allowed to operate when in AUTO mode The default setting 2 should be correct for most installations A setting of 1 is the most aggressive 8 is the least aggressive If regula...

Page 35: ...000 Sprayer Type Default setting Evc This SYSTEM CAL position is used to select the sprayer type which controls the behavior of the section valves based on whether or not the system contains a MAIN vavle EC If the sprayer system has a MAIN on off valve select EC With this setting when console is put into HOLD only the MAIN valve will shut off the individual section valves are left alone EVC If MAI...

Page 36: ...S is a nonzero number If TIPS is set to 0 then the Flow Per Boom gallons minute liters minute The filtering only affects the amount of averaging and response time applied to the displayed values All calculations and control elements of the electronic console uses the raw or the instantaneous values If filter is set to OFF then all of the displayed values are shown raw or instantaneous This can be ...

Page 37: ... AUTO MAN HOLD switch in HOLD 2 Turn the rotary dial to any of the six RED calibration positions The console will display CAL and the warning light will flash See Figure 8 2 Fig 8 2 CAL Exiting System Calibration Upon completion of the special calibration process exit special calibration by simply pressing the SYSTEM CAL button Proceed with Standard Liquid Calibration before beginning operation Be...

Page 38: ...ial position Display will read Adjust Rate Enter the value for the desired amount of change in GPH LPH to be used for making on the go rate adjustments when operating in AUTO You may set an adjust rate value for each target rate Press RATE 1 to enter the adjust rate for Rate 1 press RATE 2 to enter the adjust rate for Rate 2 and press RATE 3 to enter the adjust rate for Rate 3 Use the ADJUST switc...

Page 39: ...e CAL factor UPP Dial position Display will read Determining Distance Cal Factor UPP For the console to calculate the correct speed and measure distance and area accurately the circumference of the sensor equipped wheel must be determined Determine the circumference of the sensor mounted wheel to the nearest tenth of an inch thousandth of a meter with the following method Mark the tire with a piec...

Page 40: ... both English and Metric Use the ADJUST switch to enter this value For pressure based control no flow meter installed enter zero 0 0 as the flow meter calibration value Please refer to Fine Tuning Flow Transducer Calibration Value on page 56 FLOW CAL PSI CAL bar data data inches Rate ERROR 1 2 Gal Ac kg ha Gal N Ac liters ha Gal 1000 Fig 8 3 Dial position Display will read Theoretical Flow Meter C...

Page 41: ...mine the correct working width The working width is the width of ground being affected by any operation This should be measured to the nearest inch thousandth of a meter Your working width will be the number of nozzles on that boom section times the nozzle spacing in inches mm For example if you have 7 nozzles spaced at 20 inches the working width is 140 inches ADDITIONAL BOOM WIDTH FEATURE To adj...

Page 42: ...lon per minute of your actual application rate For example if the minimum flow rate per nozzle is 22 GPM at their minimum pressure and your spray boom has 20 nozzles all sections the minimum flow value is 4 4 22 x 20 4 4 The system will not apply at a rate lower than this value when spraying in AUTO Entering minimum flow values Each target rate may have a different setting for minimum flow Press t...

Page 43: ...must be entered for each of the three control types offered in the HARDI Mustang 3500 Flow Cal Min Flow Min Pressure Y Optional Y Y Y Y Y N N Hybrid is defined as pressure based control with flow verify Control Type Flow Pressure Hybrid Pressure Sensor Zeroing If your system is using an electronic pressure transducer you must zero the pressure sensor This procedure sets the zero point of the trans...

Page 44: ...0 inches 3 048 meters Distance UPP Speed distance area rate 1 75 inches edge 0 044 meters edge Flowmeter PPU App rate flow rate 155 0 155 0 Min Flow 1 0 0 gallons minute 0 0 liters minute Min Flow 2 0 0 gallons minute 0 0 liters minute Min Flow 3 0 0 gallons minute 0 0 liters minute Area and application rate Application rate Amount of increase or decrease per press During AUTO control Lowest allow...

Page 45: ...UTO MAN HOLD switch in HOLD 3 Hold the appropriate RATE key and the switch during power up RATE 1 English RATE 2 Metric NOTE Loading factory defaults also clears total counter pair and F1field counter pair and blanks the pressure display About Test Speed Test speed is a built in ground speed simulator that is used in performing pre field checks When a typical operating speed is entered the HARDI M...

Page 46: ...your sprayer tank with clean water DO NOT use chemicals until the entire system is completely checked out and operating properly The MASTER switch reference in this procedure is the lower right switch labeled AUTO MAN HOLD 1 Start vehicle and bring pump up to normal operating RPM Make sure pressure does not exceed safe operating limits for your system 2 Put the master switch in HOLD Turn rotary sw...

Page 47: ...AN control mode turn all active boom switches ON 7 Turn the rotary dial to the FLOW PER MINUTE position and hold ADJUST switch in the position until application rate stops decreasing The display should now read less than the desired application rate It is not normally a problem if the application rate goes all the way to zero when holding the switch as long as it goes back up when the switch is he...

Page 48: ...momentarily show the new target rate target rate adjust rate and then lock on to that rate If the application rate was correctly displayed during manual MAN operation but registered too high in automatic AUTO control the calibration value for MIN FLOW may be set too high To exit Test Speed mode place the console in HOLD turn the rotary dial to the SPEED position and press the TEST button for three...

Page 49: ...on which follows Console Appears Dead Using your test light check for 12 volts at the power source Also check for damaged power cable or reversed terminals Console requires 12 volts for proper operation Speed is Always Zero or Erratic Check for properly calibrated wheel circumference Review speed sensor installation Check for proper mounting alignment and spacing of speed sensor in relationship to...

Page 50: ...id Used is Inaccurate NOTE Make sure the sprayer s flow return adjusting valves are set properly See your sprayer s operating manual for details or see Appendix B for basic instructions This may result from an incorrectly entered FLOW CAL value If the meter has been used frequently wear may have changed the FLOW CAL value See Fine Tuning Flowmeter Calibration on page 56 Confirm that the proper wid...

Page 51: ...sole Power Cable Using a voltmeter test for voltage between pins 2 and 3 at the 9 pin connector of the console power cable If voltage test fails check fuse on system power cable Remote Run Hold Input Toggle the master switch to MAN Connect the remote Run Hold cable to the back of the console Shorting the terminals at the end of Run Hold cable together should cause the display to read rHold remote ...

Page 52: ...net in it with the pole facing out Check that the 4 magnets are in place 3 Check every second magnet has the same pole orientation so the rotor magnets are N S N S 4 Connect negative lead of multimeter to negative post of 12V battery 5 Set multimeter to DC volt 6 By turning the mill wheel slowly this will register approx 8 0 1 volt with the diode on and 0 3 0 1 volt with the diode off with every s...

Page 53: ...ol Module Using a voltmeter VM check for 12V between G an E If no voltage present check power cable fuse RPM Input Twin Force Toggle the MODE switch to RPM and disconnect the RPM sensor yellow tie from SCM Check for 12 volts between pins B white and C black of the RPM input cable red tie Using a clip lead or other jumper wire such as a paper clip bent in a U rapidly short together pins A red and C...

Page 54: ...o D should be a 12V With the negative lead remaining on G and a jumper a paper clip works well between G and C touch the positive lead to F It should measure between 5 8 and 6 8 volts If foam rate is set to 0 it will be closer to 6 8 volts if set to 100 measurement will be closer to 5 8 volts Remove jumper With the negative lead remaining at G touch the positive lead to A This is a 2 hertz signal ...

Page 55: ... operate check for broken connection between connector and valve If section test fails be sure to check number of sections setting in System Cal To test the MAIN ON OFF valve place the master switch in MAN the VM should read approximately 12 with the master switch in HOLD the VM should read 12V If MAIN ON OFF valve output test checks is good but valve does not operate check for broken connection b...

Page 56: ...APPENDICES ...

Page 57: ...urn the rotary dial to the SPEED CAL DISTANCE position Be sure the display shows 0 If not reset the distance counter by pressing and holding RESET until the display returns to 0 2 You are now ready to drive the measured course Pick a location on the vehicle to use as a marker for starting and stopping the distance counting function e g door handle mirror step You should begin to drive the course w...

Page 58: ...ctor in the lower right display See Figure below 5 When the number shown on the display matches as closely as possible the actual distance driven you have arrived at the correct calibration value To verify proper calibration repeat the procedure a second time Write down the Distance Cal Factor UPP number lower right display and keep it in a safe place If the calibration values are ever accidentall...

Page 59: ... the display reads 0 4 Place the Master Switch in MAN and run a known amount of water preferably 100 gallons or more 5 Place the console in HOLD to turn off section valves Compare the console s TOTAL FLOW reading top display with the known amount of water run If the two amounts are within one or two percent no fine tuning is required and you may continue set up If the two amounts are more than one...

Page 60: ...rn on all section valves 3 Turn the rotary switch to Flow Per Minute position 4 Toggle the master switch to MAN 5 Using the adjust switch adjust the pressure to your target pressure 6 After 30 seconds note the reading in the lower right area of the display This is the flow per nozzle in ounces per minute or liters per minute in metric 7 Using a container with fluid ounce graduation markers catch t...

Page 61: ...nces between normal operation mode and VRA mode When VRA mode is activated The 1 2 or 3 icons which normally appear next to the Rate icon in the upper display disappear leaving just the Rate icon on This indicates that the console is now in VRA mode The Target Adjust feature is disabled The console display always shows the actual application rate If the user presses the Adjust switch then the curr...

Page 62: ...ps the sprayer If the user sets the Master switch to Man it overrides the PC Hold condition console displays Phold turning the sprayer back on and allowing the user to adjust the rate manually using the INC DEC switch To return to VRA mode move the Master switch back to AUTO The console display shows the current status prescribed by the PC either a VRA application rate or Phold AUTOMATIC OVERRIDE ...

Page 63: ...in Force SC Console 26002903 3500 Console Mount Kit 26003003 3500 Console Cable 9 pin CPC to 7 pin Mixed 26003103 7 section SC Module Adaptor Cables 26003203 4 section Twin Force SC Module Adapter Cables 26001803 Power Cable 26003303 5 7 pin Extension Cable 26003403 10 7 pin Extension Cable 26001903 15 7 pin Extension Cable 26003503 20 7 pin Extension Cable 26003603 25 7 pin Extension Cable 260037...

Page 64: ...1 240951 333561 460364 420582 179767 842022 320283 717426 COMPLETE FLOWMETER ASSEMBLIES S67 EC Ø13 5mm 842081 1 GROOVE EC Ø20 0mm 842082 NO GROOVE EC Ø36 0mm 842228 2 GROOVES S67 S67 241673 728816 261093 460261 471125 178975 261093 729058 160695 722525 471125 410362 145062 637761 COMPLETE FLOWMETER ASSEMBLY EVC ESC Ø13 5mm 842191 1 GROOVE 39001203 46000803 410546 26005503 PROXIMITY SENSOR W CABLE ...

Page 65: ...loss of livestock loss of crops loss because of delays in harvesting or any expense or loss incurred for labor supplies substitute machinery rental for any other reason or for injuries either to the owner or to a third party nor can HARDI be called upon to be responsible for labor charges other than originally agreed incurred in the removal or replacement of components 3 The customer will be respo...

Page 66: ...0 MUST be approved IN ADVANCE by the Service Manager 11 Claims under this policy must be filed with HARDI within thirty 30 days of work performed or warranty shall be void 12 Parts requested must be returned prepaid within thirty 30 days for warranty settlement 13 Warranty claims must be PROPERLY COMPLETED or they will be returned DISCLAIMER OF FURTHER WARRANTY THERE ARE NO WARRANTIES EXPRESSED OR...

Page 67: ......

Page 68: ...06 Fax 559 271 3107 HARDI GREAT LAKES 290 Sovereign Rd London Ontario N6M 1B3 Phone 519 659 2771 Fax 519 659 2821 For Product Service or Warranty Information Please contact your local HARDI dealer To contact HARDI directly Please use the HARDI Customer Service number 1 866 770 7063 Or send your email to CUSTSERV hardi us com HARDI INC Visit us online at www hardi us com ...

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