Raven AccuFlow Vortex Installation And Operation Manual Download Page 75

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CHAPTER

Troubleshooting:

CHAPTER 7

TROUBLESHOOTING

WARNING

Anhydrous ammonia may be under pressure.

Before disconnecting any fittings or hoses, be

sure to purge the system of all NH

(see

Discharging the AccuFlow™ System

section on

page 61).

Summary of Contents for AccuFlow Vortex

Page 2: ...ven Industries shall not be held responsible for any modifications or repairs made outside our facilities nor damages resulting from inadequate maintenance of this system As with all wireless and sate...

Page 3: ...ooler 22 Check Valve Assembly For Multiple Section Valves Only 23 Refrigerant Line Assembly 24 One Inch Gauge Tree and Valve Assembly 25 Gauge Tree and Valve Assembly 25 Attaching the Gauge Tree to th...

Page 4: ...Pressure Cal 51 Default Calibration Values NH3 Pre sets 52 Programming HP Rate Control Viper Pro 53 Adjusting the Rate Cal 56 Operating HP System in HP NH3 Boost Mode 58 Verifying AccuFlow HP Operatio...

Page 5: ...nder the influence of alcohol or an illegal substance Be alert and aware of surroundings and remain in the operator seat at all times when operating this Raven system Do not operate the implement on a...

Page 6: ...follow instructions provided with the application system to properly discharge NH3 before performing service or maintenance Pressure gauges can fail become plugged or display incorrect pressure Slowl...

Page 7: ...cts and containers Triple rinse and puncture or crush empty containers before properly disposing of them Contact a local environmental agency or recycling center for additional information Always foll...

Page 8: ...ay damage hydraulic components Stand clear of the implement when starting the system for the first time after installing or servicing hydraulic components in case a hose has not been properly connecte...

Page 9: ...r flame cut corners fastener threads or cap screw heads hose clamp ends etc Avoid areas where the operator or service personnel might step or use as a grab bar Do not connect affix or allow hoses to c...

Page 10: ...d to conditions beyond harnessing component specifications Avoid routing harnesses in areas where damage may occur due to build up of material e g dirt mud snow ice etc Avoid routing harnesses in area...

Page 11: ...GER Exposure to anhydrous ammonia can cause severe burning blindness or death Use extreme caution when opening a previously pressurized system To avoid injury or death always wear proper personal prot...

Page 12: ...seals will result 4 Resume normal field application until the pressure gauge reads no remaining pressure is left in the AccuFlow system 5 Toggle the control console or vehicle master switch to the off...

Page 13: ...as dispersed check the pressure and temperature gauges to verify that the pressure reads zero and all parts are at an ambient temperature not frosted over 11 Open the secondary bleed valve slowly to r...

Page 14: ...an anhydrous ammonia NH3 system Operators must familiarize themselves with the system bleed valve locations and procedures before charging the system with NH3 Primary Bleed Valve Secondary Bleed Valv...

Page 15: ...uses a small amount of anhydrous ammonia from the system to reduce the temperature of the ammonia being applied The Raven AccuFlow Vortex system is available in two configurations to match the NH3 ap...

Page 16: ...Breakaway Couplers 1 1 2 2 NA Hoses from Nurse Tank Withdrawal Valves to Trailer Bulkhead Couplers 1 1 2 2 Minimized and Equal Length If equipped with bulkhead couplers Hoses from Trailer Bulkhead Cou...

Page 17: ...th Use 3 4 reducers in 1 tee 13 Vapor Tee ID 1 2 NA 14 Vapor Rows 4 NA Attempt to have at least one applicator knife in between each vapor row Toolbar 15 Toolbar or Applicator Unit NA NA Tractor 16 Tr...

Page 18: ...CHAPTER 2 14 AccuFlow Vortex and AccuFlow HP Installation and Operation Manual FIGURE 1 Application Unit System Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 15...

Page 19: ...d the overall service we provide We appreciate the opportunity to see ourselves as our customers see us and are eager to gather ideas on how we have been helping or how we can do better To serve you b...

Page 20: ...CHAPTER 2 16 AccuFlow Vortex and AccuFlow HP Installation and Operation Manual...

Page 21: ...local Raven dealer for more information and assistance When installing hoses cables and wires always take care that they cannot be pinched cut or otherwise damaged during normal operation FIGURE 1 Typ...

Page 22: ...he cooler with the base lip facing left 5 Install the 7 16 u bolt from the top of the cooler so the threaded portion of the U bolt is through the two holes on top of the mounting bracket 6 Thread and...

Page 23: ...cooler 2 Slide the bent end outlet manifold into the coupling gasket 3 Place the two parts of the coupling clamp over the coupling gasket so the bolt holes are above and below the outlet manifold 4 Us...

Page 24: ...he two parts of the coupling clamp over the coupling gasket so the bolt holes are above and below the outlet manifold FIGURE 6 Clamp Installation Detail 7 Using two 1 2 bolts and two 1 2 nuts to secur...

Page 25: ...off valve Verify that the 90 hose barb fitting if located at below the pipe 6 Secure the gauge tree manifold to the controller valve 7 Install the needle valve into the needle valve port of the gauge...

Page 26: ...tlet manifold 4 Tighten the 1 2 nuts to 80 to 100 ft lbs 5 Install a clamping u bolt over the top of the gauge tree so the threaded portion of the u bolt is through the two holes on the pipe support b...

Page 27: ...ly 1 Apply PTFE thread sealant to all threaded joints 2 Install the pipe nipple into the top of the fitting tee 3 Attach the check valve to the pipe nipple with the flow direction as shown in Figure 9...

Page 28: ...he 90 hose barb fitting 3 Secure the hose clamp over the 90 hose barb fitting 4 Slide a hose clamp over the other end of the refrigerant line 5 Slide the refrigerant line over the straight hose barb f...

Page 29: ...4 x 3 pipe nipple into one of the side ports on 1 1 4 cross 10 Install a 1 1 4 x 1 2 reducer into the other side of the 1 1 4 cross 11 Install the pressure gauge assembly into the top of 1 1 4 cross 1...

Page 30: ...E 12 Attaching the Gauge Tree to the Cooler 1 Place the cooler mounting bracket on top of the cooler 2 Use the provided large u bolts to secure the mounting bracket to the cooler 3 Place the clamping...

Page 31: ...d joints 2 Install the pipe nipple into the top of the fitting tee 3 Attach the check valve to the pipe nipple with the flow direction as shown in Figure 9 NOTE Refer to the spare parts list in Chapte...

Page 32: ...aight hose barb fitting MANIFOLD ASSEMBLY There are variations in inlet manifolds Locate the appropriate inlet manifold below and follow the appropriate instructions to install your inlet manifold DUA...

Page 33: ...pipe nipple DUAL INLET MANIFOLD SUPPORT BRACKET INSTALLATION FIGURE 17 Standard Inlet Manifold Support Bracket 1 Use three 3 8 bolts and 3 8 nuts to secure the mounting bracket to the inlet manifold s...

Page 34: ...g u bolt around the inlet manifold without installing the nuts 3 Place the inlet manifold support bracket against the bottom of the inlet 4 Feed the threaded ends of the u bolts through the holes on t...

Page 35: ...to Mounting Plate Primary Bleed Valve Secondary Bleed Valve Vapor Hose Toolbar Hose to Breakaway Bleed Circuit Pressure Hose Connection Pressure Gauge Temperature Gauge Vortex Cooler Bleed Circuit Vap...

Page 36: ...the connections is flush with the flat side of the node mounting bracket Refer to Figure 21 2 Use three bolts and nuts to secure the control node to the mounting plate 3 Use two bolts and nuts to secu...

Page 37: ...nipple 2 Install the pipe nipple into the NH3 pump as shown in Figure 23 3 Attach the 2 1 2 coupling to the secure the pump to the outlet on the bottom of the Vortex cooler Refer to Figure 23 4 Use th...

Page 38: ...nd Operation Manual INSTALLING HYDRAULIC VALVE FIGURE 24 Installing Hydraulic Valve to Vortex Cooler Bracket 1 Use two bolts nuts and flat washers to attach hydraulic valve to Vortex cooler support br...

Page 39: ...le always turn the pump off in the float position NOTE Route hydraulic hoses so that they are free of twists or kinks and will not be pinched by surrounding mechanisms Ensure at least 3 feet of hose e...

Page 40: ...e between the cooler and the standard so the standard has a full range of motion and does not contact the cooler assembly Also verify that the ball valve hands can be pulled to the full off position w...

Page 41: ...eaded joints 2 Install the vapor hose fitting into the vapor port openings WARNING Anhydrous ammonia can cause severe burning blindness or death Always work upwind of an implement with the AccuFlow sy...

Page 42: ...o the back of liquid tubes Vapor tubes should be spaced out evenly across the tool bar Avoid connecting vapor tubes on wheel tracks and adjacent rows if possible 4 Route 3 4 tubing from the 3 4 cooler...

Page 43: ...reduce risk of uneven application Raven recommends using equal length hose to all vapor knives placed at least 1 row apart BLEED LINE HOSE ROUTING 1 Apply PTFE thread sealant to all threaded joints 2...

Page 44: ...ve 6 Route the 3 8 low pressure hose to a 3 8 hose barb tee on the top side of the cooler FIGURE 32 3 8 Barb Tee 7 Connect to the hose barbs on the top of the cooler This bleeds off into the cooler s...

Page 45: ...nts and hoses to identify leaks Fix any leaks and repeat air test before charging the AccuFlow system with anhydrous ammonia If the system is pressurized but the pressure gauge on the system and the g...

Page 46: ...CHAPTER 3 42 AccuFlow Vortex and AccuFlow HP Installation and Operation Manual...

Page 47: ...PROGRAMMING NH3 RATE CONTROL ENTERING BOOM CAL The boom cal for the AccuFlow system can be calculated with the following formula Number of Applicator Knives x Spacing in inches Implement Width EQ 1 FO...

Page 48: ...Meter Cal Lb N EQ 2 Meter Cal Liter 0 506 Meter Cal Kg N EQ 3 Example 720 Gal 4 22 170 62 Lb N EQ 4 Example 190 Liter 0 506 375 494 Kg N EQ 5 ADJUSTING VALVE CAL Refer to the console Installation and...

Page 49: ...e of 150 lbs N acre at an average of 5 5 mph and a calculated implement width of 480 inches the required capacity is 150 x 5 5 x 480 66 6 lbs N min 5940 EQ 7 SI Units Given a target application rate o...

Page 50: ...This refrigerant then discharges through vapor knives installed behind applicator knives This may add extra NH3 to those rows Options to reduce the amount of refrigerant and row to row variances are...

Page 51: ...x Implement Width inches lbN min 5940 EQ 10 To convert lbN Hr lbN lbN min min x 60 EQ 11 INSTALLING AND ORIFICE HOSE BARB FITTING 1 Follow the system bleed down procedure found in the AccuFlow manual...

Page 52: ...oduct cable 7 Verify that all motorized valves are in the off position 8 Turn the AccuFlow emergency shut off valve s to the full open position 9 Connect and secure the hose from the AccuFlow implemen...

Page 53: ...e console refer to the control console s Operation manual for details 2 Toggle the master switch to the off position 3 Toggle the console to manual control mode 4 Toggle the switch for section 1 boom...

Page 54: ...CHAPTER 4 50 AccuFlow Vortex and AccuFlow HP Installation and Operation Manual...

Page 55: ...r method for connecting and charging the AccuFlow system 1 Verify that all hoses fittings and mounting bolts are securely fastened or tightened 2 Verify that the AccuFlow flow meter is connected to th...

Page 56: ...system pressures have stabilized verify that pressure gauge readings on the AccuFlow system and the nurse tank are matching If the pressure readings do not match one of the gauges may be defective an...

Page 57: ...To setup the proper HP application mode from CAN Controller Status screen press Application box FIGURE 1 CAN Controller Status Settings and Node 1 Settings 3 In Node 1 Settings screen select HP and p...

Page 58: ...CAN Controller Status b Low Supply will generate an error message if pump inlet pressure drops below set value 20 psi default adjustable from 0 50 psi from Node 1 Settings screen A setting of zero di...

Page 59: ...r Pro manual for steps on pressure transducer calibration IMPORTANT Pressure transducers must be accurately calibrated for Low Supply Max Pressure and Pump Fault errors to work properly Cal both trans...

Page 60: ...capacity Target Application Rate x Target Application Speed x Implement Width lbs kg N min 5940 60 000 EQ 1 NOTE Be sure to enter the target application rate in pounds kilograms of nitrogen per acre h...

Page 61: ...52 kg N min SYSTEM CAPACITY CHART NOTE This figure assumes all recommended plumbing practices have been followed Failure to follow to those practices will limit the system capacity to lower values The...

Page 62: ...pressure transducer reading with master switch off If the boost pump pressure rate cal is set too high excess vapor will form in the supply lines If vapor builds up in the supply lines the boost pump...

Page 63: ...e 10 System operating pressure at control valve will display as P1 and pump inlet cooler pressure will display as P2 11 As daytime temperature and nurse tank pressure increases the tractor hydraulics...

Page 64: ...CHAPTER 5 60 AccuFlow Vortex and AccuFlow HP Installation and Operation Manual...

Page 65: ...gles face shield clothing that fully covers bare skin protective suit and gloves are required when working with anhydrous ammonia products NOTE Refer to Figure 1 and table on page 63 when referencing...

Page 66: ...shut off valve Item 3 either by using the rope from the cab of the tractor or the handle on the valve itself on the AccuFlow Vortex cooler 7 Bleed and disconnect the nurse tank supply hose Item 2 from...

Page 67: ...ank Main Shut off and Bleed Valves At Bulkhead or Withdrawal Valve 2 Supply Hose Bleed Valves and Breakaway Couplers 3 Accuflow System Emergency Shut off Valve and Rope to Tractor Cab 4 Accuflow Syste...

Page 68: ...2 System Bleed and Emergency Shut off Side View Primary Bleed Valve Secondary Bleed Valve Vapor Hose Toolbar Hose to Breakaway Pressure Gauge Temperature Gauge Vortex Cooler Bleed Circuit Vapor Hose...

Page 69: ...r assembly 3 Remove the four bolts on the Vortex cooler closest to the inlet 4 Remove the inner assembly with a twist pull motion 5 Clean residue from the inner assembly and inspect the Vortex cooler...

Page 70: ...rings Raven recommends injection of nitrogen stabilizers downstream of heat exchanger components and plumbing Unit should be inspected disassembled and cleaned at the end of every season if nitrogen s...

Page 71: ...r debris 4 Clean and inspect the teflon gasket and strainer screen and replace as necessary 5 Replace strainer screen and ceramic magnets into strainer body 6 Place the teflon gasket onto the strainer...

Page 72: ...urbine and hub bearings are not worn hold the turbine bearing hub while spinning the turbine The turbine should spin freely with very little drag 7 If the bearing hub stud is adjusted or replaced repe...

Page 73: ...cked out but the flow meter still is not reading properly verify that the sensor is threaded all the way into the flow meter body and the orientation groove on top of the sensor is parallel with flow...

Page 74: ...CHAPTER 6 70 AccuFlow Vortex and AccuFlow HP Installation and Operation Manual...

Page 75: ...ooting 71 CHAPTER7TROUBLESHOOTING WARNING Anhydrous ammonia may be under pressure Before disconnecting any fittings or hoses be sure to purge the system of all NH3 see Discharging the AccuFlow System...

Page 76: ...ace if necessary b Remove all excess hose length between the nurse tank and break away coupler typically 12 feet c Remove excess hose between the break away coupler and the AccuFlow system typically 3...

Page 77: ...s The console may require repair Contact a local Raven dealer for further assistance Speed constantly displays a zero value 1 Check speed sensor cable and connectors or the port on the back of the con...

Page 78: ...61 before performing maintenance on the AccuFlow system 7 Verify that the nurse tank has a high flow valve Rate does not change in either manual or automatic control modes 1 Check the control valve ca...

Page 79: ...to HP boost pump Refer to the Verifying AccuFlow HP Operation section on page 58 for details on adjusting the remote tractor hydraulics Low supply pressure Triggered when pump inlet pressure falls bel...

Page 80: ...n an observed pressure reading 70 PSI and temperature reading 40 F The point where these two readings intersect is within the non vapor area SPEED SENSOR EXTENSION CABLE Disconnect the extension cable...

Page 81: ...ce total does not increase remove the section of cable and repeat the test at the connector that is the next closest to the node If the distance total now increases with the short no short test replac...

Page 82: ...otal volume number should increase by increments of 1 or more 5 If the total volume value does not increase remove the section of cable and repeat the test at the connector that is the next closest to...

Page 83: ...ACCUFLOW DIAGRAMS The AccuFlow Vortex one and two valve systems may be operated using standard Raven SCS control cabling Refer to the figure below for additional components used with the AccuFlow HP s...

Page 84: ...CHAPTER 8 80 AccuFlow Vortex and AccuFlow HP Installation and Operation Manual FIGURE 1 AccuFlow Vortex and HP System Diagram 054 1201 001...

Page 85: ...7 66 0 1 7 3 80 1 20321 176 70 3 57 180 5 6 5 37 21 63 127 9 9 7 5267 7 9 9 7 9 9 675 1 5 0 1 7 77 1 0 6 6 5 1 675 1 5 675 1 5 6 5 1 0 6 523 5 32 1 8 1 7 6 7 7 21 6 5 675 1 5 1 6 7 7 21 6 5 675 1 5 1...

Page 86: ...176 70 3 57 180 5 6 5 37 21 63 127 5 8 02725 5 3 0 17 1 3 3803 25 1 3803 3 9 9 5267 7 5 1 9 9 137 0 0 35 0 5 9 9 5 1 38 6 7 02 8 7 21 283 1 5229 3 0 6 7 6 7 5 3 0 17 283 1 26 1 5 8 7 35 6685 7 8 2 6...

Page 87: ...arts Replacement Parts Drawings 83 SYSTEM DIAGRAM AND REPLACEMENT PARTS FIGURE 4 Gauge Tree Sensor Flowmeter Valve Components 054 1201 001 6 5 1 2 11 9 8 4 10 7 3 7 7 13 12 15 12 11 14 1 15 14 13 12 1...

Page 88: ...nd Operation Manual FIGURE 5 1 Gauge Tree and Valve Assembly 054 1201 001 11 23 26 7 25 24 8 13 15 32 28 27 14 9 20 27 19 28 16 22 5 6 1 6 2 17 18 3 15 13 10 8 12 21 33 32 31 29 28 27 26 25 24 23 22 2...

Page 89: ...SYSTEM DIAGRAM AND REPLACEMENT PARTS FIGURE 6 Optional Outlet Kits 054 1201 001 70 3 57 180 5 6 5 37 21 63 127 0 1 7 5281 9 9 5267 7 5 9 9 675 1 5 6 5 1 0 6 9 9 137 137 8 3257 6 7 5 3 0 17 675 1 5 7...

Page 90: ...CHAPTER 8 86 AccuFlow Vortex and AccuFlow HP Installation and Operation Manual REPLACEMENT PARTS FIGURE 7 RFM 60S 60SG Flow Meter Replacement Parts 054 0159 144...

Page 91: ...System Diagram and Replacement Parts Replacement Parts 87 SYSTEM DIAGRAM AND REPLACEMENT PARTS FIGURE 8 RFM 15s 15sg Flow Meter Replacement Parts 054 0159 334...

Page 92: ...peration Manual FIGURE 9 1 1 2 Ball Valve Replacement Parts 054 0159 342 67 9 9 21752 9 9 21 2 9 9 7 0 5 9 1 3 57 180 5 6 5 37 21 02725 66 0 21752 9 9 02725 66 0 21 2 9 9 02725 66 0 67 9 9 5 7 283 5 6...

Page 93: ...ACEMENT PARTS FIGURE 10 1 Ball Valve Replacement Parts 054 0159 348 9 17 1 83675 0 1 26 6 7 67 9 9 21752 9 9 21 2 9 9 7 0 5 9 1 3 57 180 5 6 5 37 21 02725 66 0 21752 9 9 02725 66 0 21 2 9 9 02725 66 0...

Page 94: ...CHAPTER 8 90 AccuFlow Vortex and AccuFlow HP Installation and Operation Manual...

Page 95: ...ol Node 31 Installing Hydraulic Valve 34 Pump Upgrade 33 Vortex Cooler 66 C Calculating the Required Capacity 45 47 56 Calibration Boom Cal 43 Meter Cal 43 Pressure Transducers 51 Rate Cal 44 56 Speed...

Page 96: ...Strainer Maintenance Procedure 67 Vortex Cooler 65 Servicing and Storing the AccuFlow System 65 System Capacity Chart 46 57 System Diagram 79 System Diagram and Replacement Parts Replacement Parts 80...

Page 97: ...r s responsibility The Return Materials Authorization RMA number must appear on the box and all documentation including proof of purchase must be included inside the box to be sent to Raven Industries...

Page 98: ...claim and send it to Raven Industries for final approval The freight cost to Raven Industries will be the customer s responsibility The Return Materials Authorization RMA number must appear on the box...

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