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DCS 300

INSTALLATION

AND

SERVICE MANUAL

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Summary of Contents for DCS 300

Page 1: ...DCS 300 INSTALLATION AND SERVICE MANUAL ...

Page 2: ...lastic parts in the Flow Meter and motorized Control Valve Check the rotor and inlet hub assembly in the Flow Meter frequently for worn parts Excessive wear can affect accuracy Do not attempt to modify or lengthen any of the three wire Speed Sensor or Flow Meter cables Extension cables are available from your Dealer ...

Page 3: ......

Page 4: ...Manual Rev C DCS 300 10 97 Order 50 10 28 97 016 0159 577 ...

Page 5: ...L 9 3 CALCULATING GRAN CAL 11 4 VERIFYING GRAN CAL 12 5 CALCULATING VALVE CAL 13 CONSOLE PROGRAMMING 14 1 INITIAL CONSOLE PROGRAMMING 15 2 OTHER DISPLAYS 16 3 SELF TEST FEATURE 16 INITIAL SYSTEM SET UP 17 INITIAL SYSTEM ROAD TEST 18 PREVENTIVE MAINTENANCE 18 APPENDIXES 1 ALTERNATE BY PASS LINE PLUMBING SYSTEM 19 2 PROCEDURE TO TEST FLOW METER ENCODER CABLES 21 3 FLOW METER MAINTENANCE AND ADJUSTME...

Page 6: ...ds Weight of one gallon LIQUID CONVERSIONS LIQUID CONVERSIONS LIQUID CONVERSIONS LIQUID CONVERSIONS LIQUID CONVERSIONS U S Gallons x 128 Fluid Ounces U S Gallons x 3 785 Liters U S Gallons x 0 83267 Imperial Gallons U S Gallons x 8 34 Pounds Water LENGTH LENGTH LENGTH LENGTH LENGTH 1 meter m 3 281 feet 1 kilometer km 0 621 mile 1 mile 1 609 kilometers PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE 1...

Page 7: ...e a Granular Encoder a turbine type Flow Meter and a motorized Control Valve The Console mounts directly in the cab of the vehicle for easy operator use The Granular Encoder is mounted on a granular belt shaft The motorized Control Valve and Flow Meter mount directly to the framework of the spreader truck Appropriate cabling is furnished for field installation The operator sets the target rate vol...

Page 8: ...nveyor shaft and Encoder coupler fits 1 diameter conveyor shaft Secure coupler to Encoder and conveyor shafts with set screws provided 3 3 3 3 3 Install mounting tabs to Encoder as shown in Figure 1 Connect mounting tab to mounting bracket not provided to prevent Encoder from rotating DO NOT DO NOT DO NOT DO NOT DO NOT rigidly mount Encoder Encoder is to be supported by coupler ONLY FIGURE 1 4 ...

Page 9: ...hes 20cm of straight hose on inlet of Flow Meter Bend radius of hose on outlet of Flow Meter should be gradual 4 4 4 4 4 Flow must be in direction of ARROW on Flow Meter NOTE NOTE NOTE NOTE NOTE For flow rates less than 3 GPM 11 lit min mount the Flow Meter vertically with arrow pointing upward Refer to Appendix 1 for alternate plumbing diagram NOTE NOTE NOTE NOTE NOTE It is essential when using s...

Page 10: ... and route Red and White battery wires to a 12 Volt battery Attach White battery wire to the NEGATIVE NEGATIVE NEGATIVE NEGATIVE NEGATIVE battery terminal and the Red battery wire directly to the POSITIVE POSITIVE POSITIVE POSITIVE POSITIVE battery terminal See Figure 4 on page 7 DO DO DO DO DO NOT CONNECT RED AND WHITE WIRES TO THE STARTER NOT CONNECT RED AND WHITE WIRES TO THE STARTER NOT CONNEC...

Page 11: ...7 BATTERY CONNECTIONS FIGURE 4 FIGURE 4 FIGURE 4 FIGURE 4 FIGURE 4 ...

Page 12: ...ertical and then removed puts Console in operate mode See NOTE below See NOTE below See NOTE below See NOTE below See NOTE below CALIBRATION KEYS Used to enter data into the Console to calibrate the system METER CAL Flow Meter Calibration Number LIQ CAL Target Application Rate GRAN CAL Determined by Encoder and System FUNCTION KEYS Used to Display Data DATA Turn Alarm ON OFF GRAN TOTAL Total Granu...

Page 13: ... lb mile kg km 4 Target Speed ___MPH km h 5 Number Of Nozzles ___ From this information you can than calculate the volume per minute per nozzle as follows GPM GPT x lb mile x MPH 120 000 No of nozzles lit min lit MT x kg km x km h 60 000 No of nozzles Use GPM lit min and pressure to select appropriate tip from tip chart EXAMPLE EXAMPLE EXAMPLE EXAMPLE EXAMPLE 1 Application Pressure 30 PSI 200 kPa ...

Page 14: ...S The total gallons per minute GPM lit min flow rate of application must be within the range of that specified for the Flow Meter FLOW METER MODEL FLOW RANGE RFM 5 0 05 5 GPM 0 2 18 9 lit min RFM 15 0 3 15 GPM 1 1 56 8 lit min RFM 55 55A 1 55 GPM 3 8 208 lit min RFM 100 3 100 GPM 11 4 379 lit min RFM 200 200 Poly 15 200 GPM 56 8 757 lit min RFM 400 25 400 GPM 94 6 1514 lit min ...

Page 15: ...he granular belt shaft 5 5 5 5 5 Weigh the amount of granular that was caught lbs kg 6 6 6 6 6 Divide 18 000 by this number This is your GRAN CAL number Write this number down for future reference EXAMPLE EXAMPLE EXAMPLE EXAMPLE EXAMPLE Weight of material caught 90 lbs 40 8 kg ENGLISH UNITS ENGLISH UNITS ENGLISH UNITS ENGLISH UNITS ENGLISH UNITS METRIC UNITS METRIC UNITS METRIC UNITS METRIC UNITS ...

Page 16: ...L display reads 200 6 6 6 6 6 Weigh the collected granules If the actual weight is not 200 lbs perform the following calculation EXAMPLE EXAMPLE EXAMPLE EXAMPLE EXAMPLE Old GRAN CAL 200 GRAN TOTAL reading 200 Weight of collected material 128 Corrected GRAN CAL Old GRAN CAL x GRAN TOTAL reading Weight of collected material 200 x 200 312 128 Corrected GRAN CAL 312 This is the new GRAN CAL value Ente...

Page 17: ...int Digit Sets the percent away from target rate at which the Control Valve motor begins turning at a slower rate so as not to overshoot the desired rate Range 0 to 9 0 5 1 10 9 90 Dead Band Digit Dead Band Digit Dead Band Digit Dead Band Digit Dead Band Digit Allowable difference between target and actual application rate where rate correction is not performed Range 1 to 9 1 1 9 9 4 CALCULATING V...

Page 18: ... keys 2 3 4 with the key switch turned to the horizontal position Depress the key in which you wish to enter data Depress the ENTER key An E will illuminate in the display Depress the keys correspond ing to the number you wish to enter i e 7 4 3 The numbers will be dis played as they are entered Complete the entry by again depressing the ENTER key ...

Page 19: ...y US gallons or SI liters a Depressing momentarily steps the display from US to SI b Depressing momentarily steps the display from SI to US 2 2 2 2 2 Selecting US or SI a To select US or SI step with until the desired code is displayed b Momentarily depress The display will now show C Sd 3 3 3 3 3 Display C Sd Standard Valve or C FC Fast Close Valve a Depressing momentarily steps the display from ...

Page 20: ...ey labelled for 5 seconds and continue holding 2 OTHER DISPLAYS 1 1 1 1 1 To display your actual application rate LIQ per TON momentarily depress key labelled 2 2 2 2 2 To display TOTAL GRANULAR applied lb kg momentarily depress the key labelled To zero out this total at any time enter a 0 in this key 3 3 3 3 3 To display LIQUID VOLUME remaining in TANK gal lit momentarily depress key labelled 4 4...

Page 21: ...gged 8 8 8 8 8 To verify maximum pressure and rate enter 999 9 into LIQ CAL 10 into METER CAL 10 into GRAN CAL and 1000 into SELF TEST This assures that the motorized Control Valve is fully open Verify maximum pressure and LIQ GRAN rate Pressure gauge is not supplied with the DCS 300 system NOTE NOTE NOTE NOTE NOTE A pressure gauge MUST be installed to properly monitor the system 9 9 9 9 9 Adjust ...

Page 22: ...ld be followed on a regular basis 1 1 1 1 1 Flush entire system with water after use of suspension type chemicals Failure to clean system can result in crystallization of chemicals which may plug the Flow Meter lines and or tips 2 2 2 2 2 Flush and drain system before storing FREEZING TEMPERATURES MAY DAMAGE FLOW METER FREEZING TEMPERATURES MAY DAMAGE FLOW METER FREEZING TEMPERATURES MAY DAMAGE FL...

Page 23: ...With pump not running fully open main line hand valve fully open by pass 1 hand valve and completely close agitator line hand valve If positive displacement pump is used fully open pressure relief valve PRV 6 6 6 6 6 Run pump at normal operating RPM 7 7 7 7 7 If centrifugal pump is used proceed with Step 8 If positive displacement pump is used proceed as follows a a a a a Place KEY SWITCH horizont...

Page 24: ...o set the desired minimum operating pressure Minimum pressure should be approximately one half the normal pre wetting pressure EXAMPLE EXAMPLE EXAMPLE EXAMPLE EXAMPLE if normal spraying pressure is 30 psi 210kPa set minimum pressure at approximately 15 psi 105 kPa 14 14 14 14 14 Verify maximum and minimum pressures and LIQ GRAN rate by repeating Steps 11 and 13 INITIAL SYSTEM ROAD TEST 1 1 1 1 1 D...

Page 25: ...all cables test good replace Flow Meter or Encoder NOTE NOTE NOTE NOTE NOTE After testing is complete re enter correct METER CAL numbers before application APPENDIX 2 PROCEDURE TO TEST FLOW METER ENCODER CABLES Disconnect cable from Flow Sensor Hold Flow Sensor cable so that the keyway is pointing in the 12 o clock position PIN DESIGNATIONS PIN DESIGNATIONS PIN DESIGNATIONS PIN DESIGNATIONS PIN DE...

Page 26: ...turbine hub in your hand and spin turbine The turbine should spin freely with very little drag inside the turbine hub 5 5 5 5 5 If transducer assembly is replaced or if turbine stud is adjusted or replaced verify the turbine fit before reassembling Hold turbine hub with turbine on transducer Spin turbine by blowing on it Tighten turbine stub until turbine stalls Loosen turbine stud 1 3 turn The tu...

Page 27: ...n fill applicator tank with a predetermined amount of measured liquid i e 250 gallons DO NOT RELY ON GRADUATION NUMBERS MOLDED DO NOT RELY ON GRADUATION NUMBERS MOLDED DO NOT RELY ON GRADUATION NUMBERS MOLDED DO NOT RELY ON GRADUATION NUMBERS MOLDED DO NOT RELY ON GRADUATION NUMBERS MOLDED INTO APPLICATOR TANK INTO APPLICATOR TANK INTO APPLICATOR TANK INTO APPLICATOR TANK INTO APPLICATOR TANK Empt...

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