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Troubleshooting   37

TROUBLESHOOTING

Do not overlook the obvious. Check pump, boom 

control valves, hoses, improper installation, etc.

The 8605 is easy to troubleshoot if you approach 

it in an organized manner. There are four prima-

ry parts. 1) The 8605 Controller, 2) The Speed 

Sensor,  3)  The  Flowmeter,  and  4)  The  Servo 

Valve.  Your  main  objective  when  troubleshoot-

ing is to isolate the problem and find out which 

of the four parts is defective.

The 8605 has been designed with internal and 

external  protective  circuitry.  These  protective 

circuits protect the controller from damage due 

to  shorts  caused  by  pinched  wires,  or  connec-

tors being plugged in wrong. Excessive current 

draw from the servo valve is also protected.

If  the  controller  display  shows  “Low  Battery 

Power” or is dead, turn the power switch to the 

off (down) position for 1 or 2 minutes, then back 

on.  If  the  display  is  still  dead,  then  disconnect 

all cables except power from the controller and 

try again. By trial and error you can find the bad 

cable or device.

If your RATE or % ERROR becomes erratic, one 

possible cause could be the servo valve is start-

ing to require excessive current to operate. The 

controller  will  begin  to  protect  itself  by  limiting 

this current.

Extreme overheating of the controller will cause 

it  to  shut  itself  off  until  the  temperature  is  re-

duced. 

The following table will help you avoid unneces-

sary  testing  by  isolating  the  affected  sensor(s) 

and calibration numbers used for each mode.

The next step is to narrow the problem(s) down 

to  one  of  the  two  sensors.  The  top  half  of  the 

following table indicates which sensors are used 

for the various modes.

For example, assume Total Gallons is not work-

ing properly. From the table we can see that only 

one calibration number is used, the Pulses Per 

Gallon.

First double check the calibration number, mak-

ing sure that it is programmed in correctly, then 

check the flowmeter.

If  the  table  indicates  two  sensors  are  used  for 

a  mode,  such  as  Rate  Gal/Acre,  then  you  can 

isolate the faulty sensor by testing other modes 

which depend upon only one of the sensors. Us-

ing  the AREA  or  SPEED  or  DISTANCE  modes 

will test the speed sensor accuracy.

TROUBLE SHOOTING CHART

SELECTED MODE

SPEED

MPH

VOLUME

TOTAL

GALLON

AREA

TOTAL

ACRE

RATE

GAL/ACRE

GPA%

ERROR

DISTANCE

VPM

SENSOR

USED

SPEED 

SENSOR

X

X

X

X

X

FLOWMETER

X

X

X

X

CALIBRA

TION

NUMBERS

DISTANCE CAL.

FACTOR

X

X

X

X

X

PULSES/GALLON

X

X

X

X

BOOM WIDTH

X

X

X

Содержание 8605

Страница 1: ...8605 CONTROLLER OPERATOR S MANUAL DO NOT USE OR OPERATE THIS EQUIPMENT UNTIL THIS MANUAL HAS BEEN READ AND THOROUGHLY UNDERSTOOD PART NUMBER 39300018 Rev E ...

Страница 2: ......

Страница 3: ...KEYPAD 8 TOTAL VOLUME 8 TOTAL AREA 8 FIELD VOLUME 8 FIELD AREA 9 VPM 9 DISTANCE 9 SPEED 9 MENU ENTER 9 KEYS 9 TIME DATE 9 RATE 10 ERROR 10 DATA STORAGE 10 DISPLAY 11 GUIDELINES 12 PRESYSTEM CHECK 13 PRINTING REPORTS 14 EXTERNAL INPUT 15 CALIBRATION 16 DISTANCE CALIBRATION 16 GENERAL INFORMATION 16 CALIBRATION PROCEDURE SPRAYERS 17 MINIMUM FLOW RATE PROCEDURE 19 CALIBRATION PROCEDURE ANHYDROUS AMMO...

Страница 4: ...Valve 34 REMOTE RUN HOLD 34 WIRING 34 Motorized Boom Valves 35 Solenoid Valves 35 ANHYDROUS AMMONIA APPLICATIONS 36 TROUBLE SHOOTING 37 CONSOLE SYMPTONS AND POSSIBLE CAUSES 38 CABLE AND CONNECTOR 39 SPEED SENSOR 41 FLOWMETER 41 FLOW METER CALIBRATION TEST 43 SERVO VALVE 44 APPENDIX 46 51 SERIAL COMMUNICATIONS SPECIFICATIONS 46 Serial Specifications 46 Printer Specifications 46 SERIAL PROTOCOLS 46 ...

Страница 5: ...u and your operator s are not intimately familiar with proper handling procedures for Anhydrous Ammonia contact your supplier for informa tion and read all safety precautions found in the HINIKER ANHYDROUS AMMONIA MONI TORING AND CONTROL SYSTEM MANUAL Refer to manual Part No 360 000 246 Revi sion E or higher for Heat Exchangers man ufactured prior to 2007 These are painted Gray or Refer to manual ...

Страница 6: ...o insure that the operator is fully instructed and is fully aware and understands the contents of this manual Important information is contained in this manual to help insure safe and efficient operations If you have any questions about this manual or equipment discussed therein contact your HINIKER dealer 4 To The Purchaser THIS IS THE SAFETY ALERT SYMBOL IT ALERTS AN OPERATOR TO INFOR MATION CON...

Страница 7: ...ion Inline or Bypass System Configuration Stepper Motor Valve Control Up to five section control of electric solenoid valves or motorized ball valves for individual boom control Boom section widths may be individually set Selection of Rate 1 Rate 2 Manual or External Rate Control Adjustable Minimum Flow Limit Adjust Rate 1 Rate 2 on the Go Warning Lamp and audible alarm when the applica tion error...

Страница 8: ...6 Operation DWG NO 3139B ...

Страница 9: ...OTAL VOL HINIKER I O 8605 RATE RATE MANUAL 2 1 6 7 8 0 1 2 3 4 9 VPM POWER SWITCH HORN SWITCH RATE SELECTOR SWITCH BOOM VALVE ON INDICATORS BOOM VALVE SWITCH SWITCH RUN HOLD MASTER BOOM DWG NO 3137A The application rates for Rate 1 and Rate 2 are set up in calibration mode and can be adjusted on the go by pressing the Up or Down arrow keys When the Rate switch is in Manual center posi tion the Ser...

Страница 10: ...ED DIST TOTAL VOL HINIKER I O 8605 RATE RATE MANUAL 2 1 6 7 8 0 1 2 3 4 9 VPM DWG NO 3136A Total Area may be cleared to zero by depressing the TOTAL AREA key for three seconds A solid tone will warn that Total Area is about to be cleared release the key to abort Total Area is cleared at the end of the tone FIELD VOLUME Pressing the FIELD VOL key displays the current Field and Chemical numbers alon...

Страница 11: ...alculate and display speed in miles per hour anytime the SPEED key is pressed An incorrect distance calibration factor will affect speed calculations MENU ENTER Key Press the or keys to scroll through the fol lowing choices Press the Enter key to choose a selection The MENU ENTER key is used to view the menu choices 1 CHANGE FIELD CHEMICAL See steps 2 and 3 page 17 2 CALIBRATION MODE See page 16 3...

Страница 12: ...EED DIST TOTAL VOL HINIKER I O 8605 RATE RATE MANUAL 2 1 6 7 8 0 1 2 3 4 9 VPM DWG NO 3135A This is a handy feature since the operator can see and hear when the error exceeds 10 and see and hear when the 8605 automatically cor rects it The 8605 performs the Error Error calcula tion very quickly Therefore it is normal to see this mode fluctuate especially in rough ground condi tions where the speed...

Страница 13: ...n the RATE 1 RATE 2 or VARIABLE RATE modes Either increase your speed or switch to manual operation No SPD is only displayed in Rate or Error ZERO WIDTH ENTERED This is a warning that the Booms have zero en tered for implement width Enter the correct width values NO FLO This is a warning that the flow signal is missing or that the flow is too low for the 8605 to operate in the Rate 1 Rate 2 or var...

Страница 14: ...r full open or full close When this happens the pressure gauge will show minimum or maximum PSI and the Controller will dis play either MAX or MIN This indicates that you are exceeding the limits of your applicator and the 8605 can no longer maintain a constant rate per acre Sometimes it is necessary to slow down to a very slow speed in the field or on an end row Small area or rough spot etc The 8...

Страница 15: ... to 40 PSI can be used on flood jet nozzles Be sure to consult your pressure nozzle charts Using pressures that are too low will generate a poor spray pattern Very high pres sures will cause misting and also increase nozzle wear out rate A 4 to 1 change in pressure will only cause a 2 to 1 change in the flow rate Therefore the speed change must be limited to 2 to 1 For example a pressure change of...

Страница 16: ...ar to the following Field Chemical Application Record As of 1 18 pm 09 18 11 Start Date 09 18 11 Time 10 08 AM Farm Field 01 Field Desc Applicator Chemical 01 Amount Applied 00153 6 Gallons Acres 0016 4 Acres Weather Conditions Wind Speed Direction Temperature Humidity NOTES Sample Field Chemical Application Record Report Information on all previously used Field Chemi cal records can be printed by...

Страница 17: ...oller will continue to apply at the rate specified in the last received message until it receives a new message specifying a new application rate Switching to MANUAL or RATE 2 on the con troller will override the external rate input Entering CALIBRATION MODE will reset the variable rate data to the RATE 1 data as dis played during Calibration step 4 The Generic Protocol is only available in softwa...

Страница 18: ...teps 2 and 3 DISTANCE CALIBRATION The purpose of this step is to match the console distance calibration factor to the distance mea suring device you are using including RADAR This calibration process is extremely simple and fast involving nothing more than driving a pre measured distance with the Console in the DIS TANCE CALIBRATION mode Distance Calibration is not required when using the Hiniker ...

Страница 19: ...selection 2 NH3 Select 1 Spray PRESS ENTER KEY TO ADVANCE TO NEXT STEP 5 SERVO LOCATION Press keys to make selection 1 INLINE Select Inline if the servo valve is installed inline with the flow to the booms 2 BYPASS Select Bypass if the servo valve is installed in a return or agitation line back to the tank or pump inlet PRESS ENTER KEY TO ADVANCE TO NEXT STEP 6 APPLY RATE 1 10 0 GAL ACRE Use numer...

Страница 20: ...distance calibration procedures as outlined on page 16 You must do so to determine what the distance calibration factor is By performing the distance calibration on page 16 the 8605 will automatically enter the distance calibration factor for step 10 If using a Hiniker GPS Speed Sensor enter 2 00 as the Calibration number 11 BOOM 1 WIDTH 240 INCHES Use numeric keys to set value or Press key to inc...

Страница 21: ...at any time by pressing the MENU key and selecting 4 MINIMUM FLOW RATE The MINIMUM FLOW RATE is a setting that will cause the 8605 to stop reducing the flow below this minimum limit as you slow down This pre vents a poor spray pattern from your nozzles by keeping the pressure at an acceptable level NOTE the MINIMUM FLOW RATE is only avail able in the SPRAY MODE It is not available for NH3 applicat...

Страница 22: ...our local dealer 20 Calibration CALIBRATION PROCEDURES ANHYDROUS AMMONIA STEP DISPLAYED ACTION YOU TAKE 1 CALIBRATION MODE Select Calibration Mode from the Main Menu PRESS ENTER KEY TO ADVANCE TO NEXT STEP 2 FIELD NUMBER Use numeric keys to enter field number 1 99 or Press key to increase number Press key to decrease number PRESS ENTER KEY TO ADVANCE TO NEXT STEP 3 CHEMICAL NUMBER Use numeric keys...

Страница 23: ... to determine what the distance calibration factor is By performing the distance calibration on page 16 the 8605 will automatically enter the distance calibration factor for step 9 If using a Hiniker GPS Speed Sensor enter 2 00 as the Calibration number 10 BOOM 1 WIDTH 240 INCHES Enter width of applicator section 1 or total machine width if only 1 section Use numeric keys to set valve or Press key...

Страница 24: ...ontroller to the other parts of the system They are listed in the table The controller location should allow easy routing of these cables CABLE CONNECTED TO POWER BATTERY OR CAB POWER OUTLET SERVO SERVO VALVE SPEED SPEED SENSOR FLOW FLOWMETER BOOM BOOM VALVES REMOTE RUN HOLD REMOTE RUN HOLD SWITCH I O EXTERNAL RATE INPUT OR PRINTER Install the U shaped mounting bracket as shown in Figure 1 using t...

Страница 25: ...s Plug the other end of the cable into the controller connector labeled POWER If there is any doubt as to whether or not you have a 12 volt system use a volt meter to check it DO NOT connect the battery cable to the tractor starter motor or alternator Connect directly to battery IMPORTANT Make sure the power switch on controller is in the OFF position when jump start ing the tractor or charging th...

Страница 26: ...semble the hardware as shown in Figure B DO NOT tighten the set screws at this time Mount the speed sensor in the sensor bracket using the two nylon nuts Be sure the sensor protrudes at least 1 2 inch through the brack et hole See Figure C Use the 4 1 2 inch hose clamp to fasten the en tire assembly to the axle or some framework Position the entire assembly on the implement Adjust the L rod and se...

Страница 27: ...bolts on a 5 1 2 inch bolt circle The 6 bolt hub plate is for 6 9 16 inch bolts on a 6 inch bolt circle The 8 bolt hub plate is for 8 5 8 inch bolts on a 8 inch bolt circle The 10 bolt hub plate is for 10 3 4 inch bolts on an 11 1 4 inch bolt circle The 8 bolt hub plate for adjustable axial is for 8 5 8 inch bolts on an 8 inch bolt circle DWG NO 5800 ...

Страница 28: ...nterface to the radar and mount in a convenient location Connect the speed cable to the console using a speed exten sion cable not included PART 363 008 006 This standard interface is used to connect a Dickey John Radar with AMP connector to the 8605 console in a stand alone mode In the stand alone mode the radar is not connected to any other system To install connect the interface to the radar an...

Страница 29: ...ar and connect it to the Adaptive Interface adapter cable Next plug the adapter cable into the radar Con nect the Adaptive interface to the adapter cable and mount in a convenient location with wires facing down Connect the cable marked speed to the SPEED input of the Hiniker console using the proper length speed extension cable Route all cables away from hot or moving parts and secure with wire t...

Страница 30: ... location ADHESIVE MOUNT The sensor may be mounted using an adhesive designated for outside use Follow the adhesive manufacturer s recommendations for using their product Allow enough time for the adhesive to cure fully before putting vehicle into service RIGID MOUNT The sensor has a threaded insert centrally locat ed in its back It will accept a metric M3 thread ed bolt The depth of the insert is...

Страница 31: ... the satellites The green indicator will stop blinking and stay on when the sensor starts sending speed information to the module The red indicator flashes when the module is out putting speed pulses on the two speed outputs At higher speeds this indicator may look as if it is always on Speed pulses are not output for speeds below 3 MPH When first powered on the module attempts to communicate with...

Страница 32: ...ns per minute where the Inline sys tem is better suited for higher flow rates The vast majority of flow rates are between 5 and 30 gallons per minute For these rates it is recom mended to use the Inline system To determine required gallons per minute with your sprayer use this formula GPM GPA x MPH x Width ft 495 NOTE THIS SECTION ONLY DESCRIBES SYSTEMS USING THE HM860 FLOWMETER AND THE NEW STEPPE...

Страница 33: ... This line MUST have a manual control valve TANK FLOWMETER VALVE HM860 FILTER SERVO VALVE OPTIONAL VALVE MANUAL VALVE OPTIONAL BY PASS PUMP MANUAL MANUAL LINES WITH VALVE BOOM VALVES TO BOOMS DWG NO 2733 A filter is recommended before the flowmeter Recommended mounting for the HM860 Flowmeter is vertical with the arrow pointing up The Servo Valve should be mounted horizontally with the cover up to...

Страница 34: ...ANK INSTEAD OF PUMP INLET FILTER SERVO VALVE MANUAL VALVE OPTIONAL AGITATION LINES TO BOOMS DWG NO 2732 If the Servo Valve is mounted in an existing by pass line or agitation line be sure to remove any parts that may restrict the flow For exam ple some agitation lines have nozzles inside the tank this would severely limit the range of the Servo Valve and must not be used If a new by pass line is g...

Страница 35: ...IMPORTANT The pipe adapter item 4 must be installed on the inlet side of the flowmeter It s purpose is to reduce turbulence caused by hoses elbows and reducers Failure to use at least 4 inches of straight 1 1 4 inch pipe may cause the flowmeter to be inaccu rate STEP 2 Install pipe adapters items 4 5 6 7 on the flowmeter STEP 3 Install mounting bracket item 1 to flowmeter assembly using the three ...

Страница 36: ...n and dirt The Servo Valve is stainless steel Maximum op erating pressure is 400 PSI Be sure to use pipe thread sealer on all connec tions to prevent leaks The Servo Valve comes with a 20 foot cable which should be long enough to reach the tractor hitch A 10 foot cable is provided to go from the hitch to the 8605 controller Be sure to connect the 10 foot cable to the receptacle labeled Servo Both ...

Страница 37: ... WIRE 1 2 3 4 5 DWG NO 3369 TO BLACK WIRE TO BROWN WIRE TO YELLOW WIRE TO BLACK WIRE TO BLACK WIRE TO BLUE WIRE TO GREEN WIRE TO BLACK WIRE TO VIOLET WIRE TO BLACK WIRE DWG NO 3456 WIRING MOTORIZED BALL VALVE 3 WIRE Connect up to 5 three wire motorized ball valves as shown in DWG 3637 Use extension cables and make connection to the controller cable marked Boom WIRING MOTORIZED BALL VALVE 4 WIRE Co...

Страница 38: ...witch when the valve is turned OFF See figure below DWG NO 2756 INSTALLATION ANHYDROUS AMMONIA CAUTION If you and your operator s are not intimately familiar with the proper handling procedures for An hydrous Ammonia contact your supplier for information and read all safety precautions found in the HINIKER ANHYDROUS AMMO NIA MONITORING AND CONTROL SYSTEM MANUAL Refer to manual Part No 360 000 246 ...

Страница 39: ...g to require excessive current to operate The controller will begin to protect itself by limiting this current Extreme overheating of the controller will cause it to shut itself off until the temperature is re duced The following table will help you avoid unneces sary testing by isolating the affected sensor s and calibration numbers used for each mode The next step is to narrow the problem s down...

Страница 40: ...volts 2 Bad power cable or power cable fuse blown 3 Battery connections reversed or not connect ed directly to battery 4 Defective controller 5 Remote run hold switch is closed instead of open 6 Solenoid valve coil is drawing too much cur rent unplug solenoid 7 Remote RUN HOLD switch is not functioning 8 Boom width is not entered correctly or boom switch is not turned on 9 Speed sensor problem see...

Страница 41: ... Plug and unplug the connector several times and wipe dry NOTE A speed sensor cable has only one socket 3 Check crimp connections the crimp con nection in all connectors is where the wire is joined to the pin or the socket Start by sliding the connector boot back to expose the wires Figure A Gently tug on each of the wires If the wires do not pull out of the connector the connection should be good...

Страница 42: ... Orange Orange Motor Phase B 7 Black Black Black Switch Return FLOWMETER CONNECTOR OR CABLE Pin or Socket Numbers Controller Cable Wire Color Extension Cable Wire Color Description 1 Black Black Ground or Negative of 12 Volt 2 White White Signal Line 3 Orange Red 12 Volts SPEED SENSOR CONNECTOR OR CABLE Pin or Socket Numbers Controller Cable Wire Color Extension Cable Wire Color Description 1 Blac...

Страница 43: ...te On a hard surface road while traveling at a constant speed the 8605 MPH should not vary by more than two tenths of a MPH A loose wheel bearing could also cause fluctuating read outs The speed sensor can also be checked by the Con troller Program your distance calibration number to 1 00 one and select and clear distance by pressing DIST key for three seconds Put console into RUN Now each time me...

Страница 44: ...ontroller flow input Set the flow meter calibration to 1 00 Clear the total volume dis play by depressing the Total Volume key for 3 seconds The controller total volume display should count up by one each time a magnet is passed un der the bottom of the sensor sensor is removed from flowmeter 2 Make sure direction of flow arrow on flowmeter is correct 3 Check flowmeter for debris slowing or stop p...

Страница 45: ...nch ny lock nuts equally to 8 3 foot pounds 100 inch pounds The turbine should spin freely when a very small amount of air is directed into the flowmeter FLOWMETER CALIBRATION TEST All flowmeters are factory calibrated and should measure GALLONS with at least 98 accuracy If you feel the flowmeter is inaccurate and would like to test it you may do so using the following procedure and test setup A E...

Страница 46: ... question was answered yes then when in MANUAL the key should OPEN the valve to increase flow to the boom If the question was answered no then the valve is mounted in a return line to the tank In this case the key should CLOSE the valve to increase flow to the boom CALIBRATED TANK TEST SET UP SUPPLY TANK PUMP NO 1 VALVE TO SET GPM ON OFF NO 2 BALL VAVLE FLOWMETER DWG NO 1280 3 Select manual on the...

Страница 47: ... in the center manual posi tion and press and hold the or key This should drive the valve in one direction When the switch cam turns far enough to activate the position switch the stepper motor should stop and the display will read MAX or MIN If the valve does not stop its direction of travel when the switch is activated the valve should be replaced The valve should respond to both the and keys 5 ...

Страница 48: ...ed space SERIAL PROTOCOLS There are two serial protocols available with the 8605 The HINIKER protocol is our original se rial communication standard The GENERIC protocol was developed to easily allow the 8605 to communicate to most mapping systems APPENDIX HINIKER PROTOCOL HINIKER External Rate Message Format NOTE Messages should not be sent faster than approximately 1 per second If messages are s...

Страница 49: ...m 3F which denotes the hundreds value of the target application rate Character 6 This will be a hex value in the range of 30 through 39 ASCII characters 0 through 9 which denotes the tens value of the target application rate Character 7 This will be a hex value in the range of 30 through 39 ASCII characters 0 through 9 which denotes the units value of the target application rate Character 8 This w...

Страница 50: ...imum Channels Reply 24 Start of Message F0 System Message 02 Two Character Message 06 Maximum Channels 01 Maximum Channels 1 Checksum 38 5 Read Channel 1 Target Rate 24 06 02 F1 01 24 Start of message 06 Read Message 02 Two Character Message F1 Channel 1 F1 through FA possible 01 Target Rate Checksum 37 The 8605 will transmit a Target Rate Reply mes sage in response to a Read Target Rate mes sage ...

Страница 51: ... Channel 1 Data 13 Data Field Size 7F set target rate reply XX Current GPA PPA Hundreds digit XX Current GPA PPA Tens digit XX Current GPA PPA Units digit 2E Decimal Point XX Current GPA PPA Tenths digit 00 NULL 2C Comma XX Current Ground Speed mph Tens digit XX Current Ground Speed mph Units digit 2E Decimal Point XX Current Ground Speed mph Tenths digit 00 NULL 2C Comma XX Current Active Boom wi...

Страница 52: ...it 0 1 0 0 R2 R1 0 0 0 When using the 8605 with most mapping sys tems you should select the GENERIC proto col From the mapping systems menu select RAVEN 450 as the serial controller Follow the set up instructions for setting up a 450 The 8605 data logger uses the communications strings listed to pass data out through the se rial port With data logging turned on data is trig gered to be sent once e...

Страница 53: ...ins total area and field area information Format R 1 2 4 F D 1 t o t a l _ a r e a f i e l d _ area CR LF The total_area field will always be 0 0 The field_area field can run between 0 0 to 999 9 The field expands to fit the number 999 9 rolls over to 0 0 and continues to accumulate this field will contain the existing area data of the 8605 D2 Data String D2 The D2 data string contains total volum...

Страница 54: ...52 Notes NOTES ...

Страница 55: ...y Any improper use operation beyond rated capacity substitution of parts not approved by Hiniker Company or any alteration or repair by others in such manner as in our judgement affects the product materially and adversely shall void this warranty NO EMPLOYEE OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY HINIKER reserves the right to make improvemen...

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