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IntelliFlowUser Guide

Part No. 875-0180-000 Rev. A1

This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:

• This device may not cause harmful interference.• This device must accept any interference that may cause undesired operation.

COPYRIGHT NOTICEHemisphere GPS LLC Precision GPS Applications

© Copyright Hemisphere GPS LLC (2007). All rights reserved.

No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system or translated into any language or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual or otherwise, without the prior written permission of Hemisphere GPS.

TRADEMARKSHemisphere GPS and the Hemisphere GPS logo, Satloc and the Satloc logo, Mapstar, Air Star Outback Guidance and eDrive are trademarks of Hemisphere GPS. Other trademarks are the properties of their respective owners.

NOTICE TO CUSTOMERSContact your local dealer for technical assistance. To find the authorized dealer near you, call or write us at:

Hemisphere GPS LLC

4110 9 Street S.E. Telephone number: (403) 259-3311 Calgary, Alberta, Canada T2G 3C4 Fax number: (403) 259-8866 E-mail address: [email protected]

Warranty Notice

COVERED PRODUCTSThis warranty covers all products manufactured by Hemisphere GPS (the "Products").

HEMISPHERE GPS LLC LIMITED WARRANTYHemisphere GPS LLC hereby warrants solely to the end purchaser of the Products, subject to the exclusions and procedures set forth herein below, that the Products sold to such end purchaser shall be free, under normal use and maintenance, from defects in material and workmanship for a period of 12 months from delivery to such end purchaser. Repairs and replacement components are warranted, subject to the exclusions and procedures set forth below, to be free, under normal use and maintenance, from defects in material and workmanship for 90 days from performance or delivery, or for the balance of the original warranty period, whichever is greater.

PURCHASER'S EXCLUSIVE REMEDYThe end purchaser's exclusive remedy under this warranty shall be limited to the repair or replacement, at the option of Hemisphere GPS, of any defective Products or components thereof. The end user shall notify Hemisphere GPS or a Hemisphere GPS approved service center immediately of any claimed defect. Repairs shall be made through a Hemisphere GPS approved service center only.

EXCLUSIONSHemisphere GPS does not warrant damage occurring in transit or due to misuse, abuse, improper installation, neglect, lightning (or other electrical discharge) or fresh/salt water immersion of Products. Repair, modification or service of Hemisphere GPS products by any party other than a Hemisphere GPS approved service center shall render this warranty null and void. Hemisphere GPS does not warrant claims asserted after the end of the warranty period. Hemisphere GPS does not warrant or guarantee the precision or accuracy of positions obtained when using Products. Products are not intended for primary navigation or for use in safety of life applications. The potential accuracy of Products as stated in Hemisphere GPS literature and/or Product specifications serves to provide only an estimate of achievable accuracy based on:

• Specifications provided by the US Department of Defense for GPS Positioning• DGPS service provider performance specifications.

Hemisphere GPS reserves the right to modify Products without any obligation to notify, supply or install any improvements or alterations to existing Products.

NO OTHER WARRANTIESTHE FOREGOING WARRANTY IS EXCLUSIVE OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, IMPLIED OR ARISING BY STATUTE, COURSE OF DEALING OR TRADE USAGE, IN CONNECTION WITH THE DESIGN, SALE, INSTALLATION, SERVICE OR USE OF ANY PRODUCTS OR ANY COMPONENTS THEREOF, INCLUDING, BUT NOT LIMITED TO, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITYTHE EXTENT OF HEMISPHERE GPS' LIABILITY FOR DAMAGES OF ANY NATURE TO THE END PURCHASER OR ANY OTHER PERSON OR ENTITY WHETHER IN CONTRACT OR TORT AND WHETHER TO PERSONS OR PROPERTY SHALL IN NO CASE EXCEED, IN THE AGGREGATE, THE COST OF CORRECTING THE DEFECT IN THE PRODUCT OR, AT HEMISPHERE GPS' OPTION, THE COST OF REPLACING THE DEFECTIVE ITEM. IN NO EVENT WILL HEMISPHERE GPS BE LIABLE FOR ANY LOSS OF PRODUCTION, LOSS OF PROFITS, LOSS OF USE OR FOR ANY SPECIAL, INDIRECT, INCIDENTAL, CONSEQUENTIAL OR CONTINGENT DAMAGES, EVEN IF HEMISPHERE GPS HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. WITHOUT LIMITING THE FOREGOING, HEMISPHERE GPS SHALL NOT BE LIABLE FOR ANY DAMAGES OF ANY KIND RESULTING FROM INSTALLATION, USE, QUALITY, PERFORMANCE OR ACCURACY OF ANY PRODUCTS.

GOVERNING LEGISLATIONTo the greatest extent possible, this warranty shall be governed by the laws of the State of Arizona. In the event that any provision hereof is held to be invalid by a court of competent jurisdiction, such provision shall be severed from this warranty and the remaining provisions shall remain in full force and effect.

OBTAINING WARRANTY SERVICEIn order to obtain warranty service, the end purchaser must bring the Product to a Hemisphere GPS approved service center along with the end purchaser's proof of purchase. For any questions regarding warranty service or to obtain information regarding the location of any of Hemisphere GPS' approved service centers, contact Hemisphere GPS at the following address:

Hemisphere GPS LLC7560 East Redfield Road Suite BScottsdale, AZ 85260Phone 480.348.9919 Fax [email protected]

IntelliFlow User Guide

Table of Contents

1: M3 PRE-INSTALLATION . . . . . .1

Unpacking and Inspecting Procedure . . . . . . . . . . . . . . 2

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Cable Route Planning 3

Environmental Considerations . . . . . . . . . . . . . . . . . . . 4

IntelliFlow Power Connections . . . . . . . . . . . . . . . . . . . 5

IntelliFlow Cable Interconnection Diagram . . . . . . . . . 6

IntelliFlow Motor/Valve/ Flow Turbine Assembly . . . . 7

IntelliFlow Interconnections and Order Numbers . . . . 9Cable Assembly, External, IntelliFlow, Spray Off, AUX, M3 Rev B (part number 05-F-2010) 9

Cable Assemby, External, IntelliFlow Motor Valve, Rev B (part number 05-F-2001) 10

2: M3/INTELLIFLOW INSTALLATION . . . . . . . . . . . . . .13

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Installation Guidelines for IntelliFlow Unit . . . . . . . . . 15

3: INTELLIFLOW . . . . . . . . . . . .17

Interfacing the M3 to IntelliFlow (AirTrac Required) . 18

i

4: FLYING FLAGMAN . . . . . . . . .29

Pre-Installation Requirements . . . . . . . . . . . . . . . . . . 30Power Requirements 30

Grounding Requirements 30

GMU Interconnections and Order Numbers . . . . . . . . 31

GMU Aux Switch Connections . . . . . . . . . . . . . . . . . . . 32

Interfacing the Flying Flagman to IntelliFlow . . . . . . 34

Calibration Factor Observations . . . . . . . . . . . . . . . . . 36

Flow Diagnostic Run Screen . . . . . . . . . . . . . . . . . . . . 38

APPENDIX A: M3/INTELLIFLOW TROUBLESHOOTING . . . . . . . . . .41

APPENDIX B: FLYING FLAGMAN TROUBLESHOOTING . . . . . . . . . .55

APPENDIX C: SPAY OFF UNIT . .71

Spray Off Interface Specifications . . . . . . . . . . . . . . . 72

Spray Off Interface Installation . . . . . . . . . . . . . . . . . 73

Installation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 77IntelliFlow, Spray off, AUX, M3 Cable (Part number 05-F-2010) 77

Cable Assy, External, Spray OFF, M3 Cable (Part number 05-F-2015) 78

ii


APPENDIX D: PARTS LIST . . . . .79

INDEX . . . . . . . . . . . . . . . . . . . . . .85

iii

1: M3 PRE-INSTALLATION

Unpacking and Inspection Procedure

Pre-Installation

Environmental Consideration

IntelliFlow Power Connection

IntelliFlow Cable and Interconnection Diagram

IntelliFlow Motor/Valve/Flow Turbine Assembly

IntelliFlow Interconnections and Order Number

1: M3 Pre-Installation

UNPACKING AND INSPECTING PROCEDURE

Follow this procedure when unpacking and inspecting the material:

1. Ensure that the number quantity (number of containers) delivered agrees with the shipping invoice upon receipt from the carrier. File a claim with the carrier if the number of containers does not agree with the shipping invoice.

2. Ensure that the delivered containers are not physically damaged. The container should be immediately opened and the contents inspected if the container is damaged. Inspect for physical damage, such as nicks, dents, scratches, etc. File a claim with the carrier if there is any damage.

2


PRE-INSTALLATION

It is important that the installer is familiar with the equipment interconnection cabling prior to installation. The installer should refer to the additional paragraphs in this chapter for system and interconnecting diagrams.

This section deals with the following topics:

• Cable route planning

• Environmental considerations

Cable Route Planning

Please ensure the following when planning cable routes:

• Cables are to be installed without stress on the connectors.

• Cables are to be secured to avoid the effects of excessive vibration.

• Avoid areas where cables may be pinched.

• Avoid running cables where they will interfere with normal operation of the aircraft.

• Avoid placing cables close to sources of interference.

• Avoid looping cables.

3


ENVIRONMENTAL CONSIDERATIONS

The system units are suitable for use in a protected from environmental elements. Before using the equipment in severe conditions, above or below the specified temperature range, consult with Hemisphere GPS Air Product Support Group.

Operators should handle aircraft system units with care even though the system units are designed to tolerate handling, movement and vibration.

4


INTELLIFLOW POWER CONNECTIONS

Figure 1-1 shows the IntelliFlow’s power connections.

Figure 1-1. IntelliFlow’s power connection

IntelliFlowcontroller

Aircraft power24 to 36 Vdc

Good frame/fuselage grounding point

10 Amp breakerPower cable (05-F-3731)

5


INTELLIFLOW CABLE INTERCONNECTION DIAGRAM

Figure 1-2 provides the IntelliFlow cable interconnection.

Figure 1-2. IntelliFlow cable interconnection

P4: Spray off

P2: Flow meter

P3: To M3

P1: IntelliFlow

Pressure switch

6


INTELLIFLOW MOTOR/VALVE/ FLOW TURBINE ASSEMBLY

Figure 1-3 provides and example of a common installation of the IntelliFlow’s motor, valve and flow turbine. Other assemblies are possible.

Figure 1-3. IntelliFlow motor/valve/flow turbine assembly

It is preferable to connect the IntelliFlow units in the following order:

1. Aircraft by-pass valve

2. Strainer

3. IntelliFlow flow turbine

4. IntelliFlow valve/motor

5. Boom

The reason for installing the flow turbine unit before the flow control valve is to avoid minimum turbulence around the flow turbine unit. If for physical installation reasons the IntelliFlow turbine and IntelliFlow motor valve can not be installed according

Flow

Flow meter

Hose clamps(12 each)

Flow direction

2” hose

1.5” x 2” x 2” (09-C-2000)

Hose clamps (26-F-6863)

7


to upper diagram, units can be inverted. It is recommended to maintain a ratio of 10 to 1 of hose ID going into the flow turbine and a ratio of 5 to 1 of hose ID between the turbine and IntelliFlow motor valve. The reason for this separation is to ensure that the turbulence does not affect flow control parameters.

8


INTELLIFLOW INTERCONNECTIONS AND ORDER NUMBERS

Cable Assembly, External, IntelliFlow, Spray Off, AUX, M3 Rev B (part number 05-F-2010)

Figure 1-4 provides theconnection diagram for the IntelliFlow, spary off, aux, M3 and DNTI flow meter.

Figure 1-4. Connection diagram

RED, 22AWG

BLACK, 22AWG

BLU/WHT, 22AWG

RED/WHT, 22AWG

BLK/WHT, 22AWG

ORG/WHT, 22AWG

WHT, 22AWG

Hopper +

Hopper -

Flow1 +Flow1 -

GRD

Flow2 +

Flow1 +

Shield

Shield

BLK/WHT, 22AWGCTS

RTS

ORG/WHT, 22AWG

BLU/WHT, 22AWG

RED/WHT, 22AWG GRD

12+

BLK/WHT, 22AWG

BLU/WHT, 22AWG

GRD

TX M3RX M3

Shield

9


Cable Assemby, External, IntelliFlow Motor Valve, Rev B (part number 05-F-2001)

Figure 1-5 and figure 1-6, on pages 10 and 11, provides the completed cabe and connection diagram for the motor valve.

Figure 1-5. Completed cable

5.5 ft

12.5 ft

Switch, 10A, DPDT7343K82

(89-T-1050)Detail B

IntelliFlow Motor/valve

Label(501-560)

Connector, 8P male, BendixPTOA-16-8P(SP)

(32-A-3000)Detail A Cable, 9C, 16 AWG, shielded

(18-C-0450)

Connector, 5P, feale, BendixMS3116F-14-5S(SR)

(32-A-3280)or

32-A-3285 Connw/ 32-A-3286 shell

Detail C

Cable, 9C, 16 AWG, shielded(18-C-0450)

10


Figure 1-6. Connection diagram

GRN

ORG

WHT

BLK

WHT/BLK stripeGRN/BLK stripe

BRN/BLK stripe

N/C

Shield

ORG

BLKWHT

BLU

RED

Note2PL

Bypass switch

IntelliFlowmotor valve

P4 label

Air open and splicingconnections made at SW1

11

2: M3/INTELLIFLOW INSTALLATION

Installation guidelines

Flow Diagnostic Run Screen

2: M3/IntelliFlow Installation

INTRODUCTION

Chapter 2 offers installation information relating to the IntelliFlow device, control valve and flow turbine unit. Chapter 2 covers the following topics:

• Installation guidelines for the IntelliFlow unit

• Calibration factor observations

14


INSTALLATION GUIDELINES FOR INTELLIFLOW UNIT

Install the flow meter in the down flow position, aft of the IntelliFlow regulating valve when possible.

It is important to maintain a reasonable distance between the aircraft regulating bypass the valve and the flow turbine meter; when possible, no less than 8 inches.

It is best to install one or two support fittings from the belly of the aircraft close to the valve and flow meter. These fittings should not be connected directly to the valve or flow meter; preferably a stainless wrap-around strap and supporting piece should be used.

If a pressure switch is used, the pressure adjustment for the switch should be 50 percent of the minimum spray boom pressure required. For example, if the minimum boom spray pressure is 20 pounds, adjust the pressure switch to 10 pounds. To adjust switch, remove upper rubber stop and adjust Allen screw head inside top of switch. The switch is N/O (Normally Open); The contacts will close when the required pressure is correct. Use a multi-meter or low voltage (1.5 D.C.) and bulb to indicate when switch contacts are closed.

15

2: M3/IntelliFlow Installation

Figure 2-1. Installation diagram

The wires should be connected as follows when connecting the wires from the tourchscreen/M3 and the IntelliFlow to the pressure sensor:

• Both black wires together

• Red wire from the IntelliFlow cable should be connected to the white wire from the M3 aux switch cable

Aircraftflow pump

Aircraftbypass valve

Strainer

Flow turbine meter

IntelliFlowvalve Boom

Pressure sensor

16

3: INTELLIFLOW

Interfacing the M3 to IntelliFlow (AirTrac required)

3: IntelliFlow

INTERFACING THE M3 TO INTELLIFLOW (AIRTRAC REQUIRED)

To interface the M3 AirTrac software to the Intelliflow/FDG/Spray OFF controllers:

1. Open the flow control Setup screen in AirTrac to initialize the M3 and hardware. “Controller FOUND” will appear below

the in the flow control Setup screen on intialization.

Note: The Hemisphere GPS IntelliFlow, Fire/Dry and Spray OFF controllers are automatically detected by the M3 AirTrac software.

18


2. Click to search for a connected controller if the “Controller FOUND” message does not appear.

3. Click in the AirTrac screen to open the Setup 2 screen.

19

3: IntelliFlow

4. Click in the Setup 2 screen to get to the Flow Control Setup screen. The detected controller can be seen in the upper left corner.

20


5. Click to get to the Flow Control Advance Setup screen. The detected controller type and software version can be seen in the upper left corner.

21

3: IntelliFlow

Note: The Flow Control Advanced Setup screen has TWO buttons that will take you to specific IntelliFlow and FDG dialog screens:

• opens the INTELLIFLOW Parameters screen.

• opens the Test Controller Parameters screen. The test dialog screen is ONLY for IntelliFlow controller, if connected.

22


6. Click in the Flow Control Advanced Setup screen to open the INTELLIFLOW Parameters screen. This TEST screen is ONLY used for the IntelliFlow controller.

7. Click Flow Control Advance Setup screen to get to the Hemisphere GPS Air Controller Parameters screen. This parameters screen is primarily for the Inteliflow controller.

23

3: IntelliFlow

8. Click .

9. Enter a Turn Around Delay (TAD) factor, in milliseconds, in the TAD box. This is the time added to the OPEN or CLOSE timings when the valve must reverse direction, thus providing the means to take any mechanical backlash. The default time is 40 milliseconds. The typical selection is between 20 and 50 milliseconds.

10. Observe the controller version # and Compile Date next to

the .

24


11. Click to get to the Advanced Setup screen to get to the Advanced Setup 2 Screen.

25

3: IntelliFlow

There are two buttons on the screen. is only used when a “Spray OFF” only cable is connected. This means that no wet or dry controller is connected. The screen will indicate “YES” or “NO” if the Spray OFF button is toggled.

Note: The Spray OFF button will turn to grey and return to “NO” after setting the Spray OFF button to “YES” and a valid wet or dry connector is connected to the M3.

26


12. Click in the Advanced Setup 2 screen to get to the Subscription Authoritizations screen. This screen is used to enter the subscription authorization number received from Hemisphere GPS technical support for each required feature.

To activate the required feature:

1. Provide technical support with your exclusive M3 “This Unit Serial #.” This is only required once for a hard drive.

2. Inform CS of your required feature. For example, PMaps & Spray OFF.

27

3: IntelliFlow

3. Select the correct features in the after receiving the activation code from TS.

The button can be used if needed.

4. Click .

5. Enter the activation code.

6. Press the enter key.

7. will be active.

8. Click and observe the message at the bottom of the screen. Typical messages include:

• “The Above Indicated Feature is ACTIVE”

• “Sorry, no subscription, try again”

28

4: FLYING FLAGMAN

Pre Installation Requirements

GMU-1 Interconnections and Order Numbers

GMU-1 Aux Switch Connections

Interfacing the Flying Flagman to the IntelliFlow

Callibration Factor Observations

Flow Diagnostic Run Screen

4: Flying Flagman

PRE-INSTALLATION REQUIREMENTS

Power Requirements

The power requirement for the Flying Flagman GMU system is 24 to

36 Vdc. The power requirement for the IntelliFlow® system is 24 to 36 Vdc. If the electrical condition of the aircraft wiring is unknown, it is recommended that the power cables be wired from aircraft master switch to the GMU and IntelliFlow breakers. This may require the installation of a protection breaker close to the master switch relay.

Grounding Requirements

Good grounding is essential for trouble free operation of the GMU unit. Grounds should be connected to the GMU case, GMU power cable, IntelliFlow case, clutch/brake interface control ground cable (black), IntelliFlow power cable and to the IntelliMap power cable. It is recommended that these grounds be connected together at one single point to the frame/fuselage for easy maintenance. The grounding point should be a perfect electrical connection. Some case may require connecting grounding cables to battery NEGATIVE ground points on the aircraft frame/fuselage.

30


GMU INTERCONNECTIONS AND ORDER NUMBERS

The standard DGPS Flying Flagman system consists of a GMU with internal logger and a keypad.

Hemisphere GPS is able to offer a wide range of options to suit the end user’s requirements because of our on-going research and development program. This makes the system flexible. Third party equipment has been designed to be used with the system. The following drawings show that a wide range of commercially available equipment such as radios can be connected to the system.

The information in this section consists of drawings of the system interconnections. The associated Items Lists giving Hemisphere GPS Air part numbers are in Appendix B. Information provided is as follows:

• System interconnections

• GMU parts list and order numbers

• GMU parts list and order numbers

31

4: Flying Flagman

GMU AUX SWITCH CONNECTIONS

Figure 4-1 displays the GMU aux switch connections.

Figure 4-1. GMU-1/TNG aux switch connections

Aux -switches(05-C-1352)

cable

1

2

3

4

5

6

7

Table 4-1: GMU-1/TNG aux switch connections numbering

Number Color Description

1 Red Swath advance

2 Blue Swath decrease

3 Orange Break

4 Green Mark

5 Brown Resume

6 White Hopper on/off

7 Black Completing circuit

32


See Figure 4-2 for an example:

Figure 4-2. GMU aux switch connection example

Warning!

The black ground wire should not be connected to the aircraft ground or, at any time touch part of the fuselage. This wire should not be connected to the shield of the aux switch cable.

The black ground wire is the logic return ground for the GMU’s remote switch functions. The black ground wire is used as the common return for the other colored remote switch wires.

Swath Adv button

Break Button

Spray on/off

RED wire from IntelliFlow

BLACK wire from IntelliFlow cable

RED wire from GPU

BLACK wire

ORANGE wire from GMU

BLACK wire

WHITE wire from GMU

BLACK wire

Pressure switchGMU aux cable

33

4: Flying Flagman

INTERFACING THE FLYING FLAGMAN TO INTELLIFLOW

Use the Run Screen 9 to observe the following information:

The Run Screen 9 information is as follows:

• APP: Instant doses applied

• REQ: Selected required does

• LPM: GPM or LPM

• VOL: Total accumulated volume on spray line or segment

• TOT: Total volume applied since start of block or field

• REM: Remaining load in hopper

To use the Run Screen, press 0,0 to observe the following information:

34


The Run Screen 0,0 information is as follows:

Line 1 of the text shows the following:

• A: Shows the number of gallons per acre being applied.

• R: Shows the number of gallons per acre required.

• P: Shows the type of pattern being flown.


• LD: Shows the number of lines sprayed.

• LS: Shows the number of lines skipped.

• F#: Shows the field number being sprayed.


• REM: Shows the remaining gallons in the hopper.

• N: Shows the number of times a line has been flown.

• PA: Shows the number of GPA/LPH applied to each line.


• SW: Shows swath width that has been set. The width can be in meters or feet. Meters will show decimal readings and feet will show whole values.

• FA: Shows accumulative number of GPA/LPH being applied for the current field.

At this point, the IntelliFlow device will regulate the flow automatically according to changes in speed, swath and flow pressure changes.

35

4: Flying Flagman

CALIBRATION FACTOR OBSERVATIONS

The CAL factor value depends on whether the CAL factor given by the turbine manufacturer is specified in gallons or liters.

The Hemisphere GPS flow turbine CAL factors are in pulses per gallon. The correct CAL factor is located around the turbine sensor.

The CAL factor that must be entered into the GMU is the same as for the turbine unit if the spray units are in gallons and the flow turbine CAL factor is pulses per gallon.

The final entered CAL factor is close to 3 to 4 percent less than the manufacturer’s CAL factor given against water when a flow turbine meter is new and the metered flow is not water.

The following examples are given for water:

Example 1:

The Hemisphere GPS (15 to 180 GPM) flow turbine meter with 382 pulses per a gallon marked when new (part number 29-C-0305), would require entering into the GMU (Setup/8/3) at 3 percent less (370.54 pulses per a gallon), at 4 percent less (366.72 pulses per a gallon).

Note: Keep a personal record of the turbine CAL factor according to turbine serial number.

36


Example 2:

The Hemisphere GPS (15 to 180 GPM) flow turbine meter with 382 pulses per a gallon (part number 29-C-0305), but converted to pulses per a liter, would require entering into the GMU (Setup/8/3) at 3 percent less (97.88 pulses per a liter), at 4 percent less (96.87 pulses per a liter).

The CAL Factor turbine flow unit conversions are:

Convert gallons to liters: X 3.785411

Convert liters to gallons: x 0.264173

37

4: Flying Flagman

FLOW DIAGNOSTIC RUN SCREEN

The IntelliFlow will go through an open and close cylce and then position itself 3/4 open during a normal power sequence.

Check the following if the control valve motor does not rotate correctly:

• Is the by-pass switch in normal?

• Is the pressure sensor circuit shorted?

• Check the power to the IntelliFlow device.

• Check the 10 Amp breaker and/or fuse on the IntelliFlow control box.

The IntelliFlow status run screen is activated by entering the following:

DISPLAY,7

Press the Run Screen key to exit this screen.

Note: This could be normal if using a microswitch on the spray handle.

Valve position number

38


Pot readints determine the valve positions:

• 3250 = Valve fully closed +/- 50

• 2650 = 1/4 open +/-50

• 2050 = 1/2 open +/-50

• 1550 = 3/4 open +/-50

• 1050 = Valve fully open +/- 50

The string format is as follows:

&FC, 145.0, 20.1, C4, 1547, 33876 *5C

1. Header (Not important to user)

2. LPM (Liters per Minute)

3. Instant application rate in LPH (Liters per hectacre)

4. Status: 64=Initialization, 44=Sensor open (no spray), C4=Sensor closed (spraying), E4=Motor moved

5. Valve position (see above)

6. Turbine pulses since IntelliFlow initialization or power up

7. Checksum (not important to user)

Note: The above valve position values can change according to valve typ and size.

39

APPENDIX A: M3/INTELLIFLOW

TROUBLESHOOTING

Appendix A: M3/IntelliFlow Troubleshooting

Basic IntelliFlow Aircraft Troubleshooting

In normal operation, apply aircraft power to the IntelliFlow control unit. Note the following:

• Wait 10 to 15 seconds for the IntelliFlow controller microprocessor to initialize. The microprocessor startup can be heard with a low beep if ambient noise is low.

• Wait and listen for the control valve motor rotation. The motor will rotate to fully open, rotate to fully closed, then finally reposition to 3/4 open.

If the IntelliFlow does not cycle:

1. Ensure that the override switch is in the normal position.

2. Ensure that there is power to the IntelliFlow controller and controller fuse.

3. Ensure that the pressure switch is normally open and working properly.

4. Check the fuse.

• Confirm that the aircraft power has been removed from the IntelliFlow controller.

• Remove the fuse from the IntelliFlow controller and inspect the fuse for signs of over current.

Note: Voltage sent to the Normal/bypass switch from the IntelliFlow controller does not pass through the 10 Amp fuse on the controller. This is a security feature in case the IntelliFlow controller malfunctions, allowing the control valve motor to rotate to the open position.

42


5. Check pressure switch.

• Remove the Aux switch I/O connector plug, where the pressure switch connects, from the IntelliFlow controller.

• Reset the system and check for normal operation. If the system responds, then there is a problem with the pressure switch.

If the valve functions properly, but the system still will not meter:

1. Manually spin meter and check for the system response.

2. Make sure the pressure switch is triggered or the system will not respond to the meter.

Note: If the pressure switch is stuck in the closed position, then the valve will not move.

43


If valve motor rotation is normal:

1. Check the voltage across the flow control sensor contacts if the motor does not rotate. The voltage should be logic 5 VDC.

2. Check the sensor cabling and/or sensor if the voltage across the sensor is 0 Vdc or less than 4 Vdc.

3. Disconnect the jumper across the pressure sensor if the operation in number 11 and 12 are normal.

4. Maintain power to the IntelliFlow control unit.

5. Observe the flow status/flow position.

6. Toggle NORMAL/BYPASS to bypass the position. The motor will fully open.

Valve Position:


• 1550 = 3/4 open +/- 50

7. If the DISPLAY, 7 Run Screen is blank or the status does not change, the most probable causes are:

• Defective IntelliFlow control unit (serial port problems) and/or

• Incorrect M3 setup. See Chapter for further information about flow screens and correct setup parameters.

8. A transducer sensor can be connected to the cable that is normally connected to the flow turbine unit if a spare transducer is available. Pulses can be generated and observed on the CPU by passing or tapping an iron object over the pick-up point of the sensor. This can also be used as a general reference to the working condition of the IntelliFlow control

44


unit and M3. Simulated flow information can be observed in Display, 7 and Run Screens 9 and 00.

9. Check the following if the unit is blowing fuses:

• Fuse is lower incorrect valve

• Aircraft IntelliFlow cable installation

• Aircraft IntelliFlow grounding connections

• Aircraft battery charging system, alternator/regulator/etc

• Aircraft battery state (common problem)

10. In addition to the following procedures, check the following:

Note: These simulated pulses are not sufficient for accurate testing, but are sufficient for checking cables, IntelliFlow control unit I/O ports, interface between the IntelliFlow control unit and M3 and general display operation. Adjust for 200 Hz sqare wave, amplitude close to 150 mv, 0 offset, If a simple function generator is available. Connect the FG to the sensor connector to produce pulses and check dynamically the IntelliFlow system. See the next system, “IntelliFlow Bench System Testing” for additional instructions.

Warning!

Do not install fuses greater than 10 Amps for the IntelliFlow control unit. Use the same type of fuse. A greater fuse valve will cause internal damage to the IntelliFlow control unit.

45


• Check all wiring connections and terminal strips.

• Check that water or chemicals have not seeped into the IntelliFlow control unit or motor control unit. It is a good practice to have the water resistant canvas cover over the motor head if the aircraft is flown under adverse conditions.

• Check that the aircraft electrical system does not experience noisy or transit voltage problems. The IntelliFlow control unit can operate within a range of 20 to 32 Vdc. The voltage range must exceed 20 Vdc to modulate the motor and valve mechanism at the desire time rate.

• Check that the sensor unit and connector do not have water or chemicals inside.

• If the flow turbine unit that does not respond correctly or does not indicate pulses/flow on touchscreen, the problem is generally caused by a gumming of the turbine blades and internal bushings.

• If highly corrosive products are used, it is recommended that the valve stem be lubricated with a few drops of pneumatic turbine lubricating oil or, if not available, low viscosity lubricating oil every 20 to 30 hours of spray time.

Note: This will avoid ground loops and faulty connections. Above all, avoid shorts to ground that will damage the IntelliFlow control unit and/or motor control unit. Check the IntelliFlow Control Unit grounding cable and grounding lugs.

Note: This can be avoided by washing the hopper/boom system thoroughly and methodically after spray sessions.

Note: If the flow turbine unit is totally bummed-up, the unit must be removed and cleaned on the bench. This requires disassembling the unit and reassembling it.

46


This will avoid gumming and/or chemical corrosion buildup around valve stem and/or gland sealing components. Penetrating oil can be applied if required. Use products

such as WD-40® or any quality penetrating oil before lubricating.

• The valve stem gland-retaining nut must not be tightened without due understanding of the sealing method of the valve stem. Any incorrect adjustment to the tension of the gland-retaining nut can adversely change the torque required to rotate the valve stem. This will cause the motor valve transmission and/or motor to over work, possibly causing damage.

Note: If the valve stem starts to gum-up, the motor valve will not respond to the IntelliFlow commands with the desired response. If the valve stem becomes too tight this can be detrimental to the motor valve transmission and motor, and cause excessive current through the power IC chip inside the IntelliFlow control unit.

47


IntelliFlow Bench System Troubleshooting

1. Confirm that the‘ bench power is removed from the IntelliFlow control unit.

2. Remove the fuse from the IntelliFlow control unit and inspect the fuse for signs of over current.

3. Connect the power cable and the control valve motor cable to the IntelliFlow control unit.

4. Connect the control valve motor to the control valve motor cable.

5. Toggle the normal/bypass switch to the normal position.

6. Toggle the flow sensor switch to the open position.

Note: It is mandatory to have a bench setup with known working cables and proven test units for successful. For example, IntelliFlow control unit, control valve motor, IntelliFlow cable set up and a M3 unit with all the cables and accessories. General test equipment is needed. If a simple function generator is available, adjust if for 200 Hz square wave, amplitude close to 150 mv, 0 offset. Use a toggle switch for sensor logic cable.

Note: The following procedures will vary depending on which unit is being tested.

Note: Voltage sent to the normal/bypass switch from the IntelliFlow control unit does not pass through a 10 Amp fuse on the control unit. This is a security feature in case the IntelliFlow control unit malfunctions, allowing the control valve motor to rotate to the open position.

48


7. Apply 28 Vdc bench power to the IntelliFlow control unit. Note the following:

• Wait 10 to 15 seconds for the IntelliFlow control unit microprocessor to initialize.

• Note the control valve motor rotation. The motor will rotate to fully open, then rotate to fully closed, then finally reposition to 3/4 open.

• If the control valve motor does not rotate:

1. Power to the IntelliFlow control unit must have the correct current requirement.

2. Control valve motor if under test.

3. IntelliFlow control unit if under test.

If the valve motor rotation is normal:

1. Remove the bench power from the IntelliFlow control unit.

2. Connect the aux switch I/O connector to the IntelliFlow control unit and M3 mainframe.

3. Confirm that the normal/bypass switch is in the normal position.

4. Apply bench power to the IntelliFlow control unit.

5. Wait 10 to 15 seconds for the IntelliFlow control unit microprocessor to initialize.

6. Note the control valve motor position. The motor will rotate to fully open, rotate to fully closed, then finally reposition to 3/4 open.

7. Check the voltage across the sensor toggle switch if the motor does not rotate (the voltage should be logic 5 Vdc).

8. Check the IntelliFlow control unit if the voltage across switch is 0 Vdc or less than 4 Vdc. This could be a possible internal logic problem.

Note: Microprocessor startup is a low beep.

49


If the previous operation is normal:

1. Toggle the sensor switch to the closed position.

2. Power cycle the IntelliFlow control unit. The control valve motor should not rotate.

3. Check the IntelliFlow control unit if the motor rotates with the toggle switch is closed.



2. Toggle the sensor switch to the open position.

3. Observe the flow status/valve position on the left side of the viewscreen on the display map.

4. Toggle the sensor and observe the status change from 44 to C4 and visa versa.

5. Toggle the normal/bypass switch to the bypass position, motor fully open.

6. If the Display, 7 Run Screen is blank, then the most probable causes are a defective IntelliFlow control unit (serial port problems) and/or incorrect M3 setup.


8. Toggle the sensor switch to the closed position. If the toggle sensor switch is in the open position, the pulses, GPM/LPM, Area and Gal/Ac/Lit/Ha will not be displayed and will not change value on the touchscreen under the following simulated conditions.

9. Connect a GPS antenna to the M3. Connect a differential source to the M3 if possible.

10. Connect a function generator, adjusted for 200 Hz square wave, amplitude close to 150 mv, 0 offset, to the cable that connects to the flow turbine unit sensor.

Note: The flow status/valve position must be selected to observe it on the viewscreen.

50


11. These generated pulses will provide a stable flow source for accurate bench tests. This dynamic data interchange of information between the IntelliFlow control unit and the M3 mainframe can be evaluated using the M3-Display.

12. The test/simulate menu function allows the user to test the operation of the M3 system by using GPS position utlities to stimulate the flight pattern without the need to fly the airplane.

13. Simulate the flow rate by using a function generator and GPS position utility for testing.

14. Check the touchscreen to confirm simulate.

15. It is important to keep the field and flow parameters within a reasonable range of values to accommodate the flow pulses received from the function generator.

16. When the M3 is in the simulate run mode, the speed can be changed by using the up/down arrows on the touchscreen. Each key is equal to 1 mph +/-

17. An additional test can be made to the IntelliFlow control unit and control valve motor by using the 05-N2148 download cable and notebook.

• Connect the download cable to the IntelliFlow control unit.

• Connect the power cable to the IntelliFlow control unit.

• Connect the power/control table to the control valve motor.

• Toggle the bypass/normal switch to normal.

• Connect the opposite end of the download cable to the notebook (Com1).

• Us a PC communications application like Proccom Plus® or

Windows® HyperTerminal®, etc.

• Set the profile to Com1, 38400, 8, 1.

• Apply power to the IntelliFlow control unit.

51


• Observe the string in the terminal output after the IntelliFlow control unit initializes.

• Enter the lower case command to “open” and “close the the control valve motor in the terminal screen mode or chat mode.

• Indicate the time, in milliseconds, to move the control valve motor.

Example: open 50 open 135 open 2000 close 45 close 80 close 2000

• These open and close tests can be used to verify the IntelliFlow control unit and control valve motor internals for correct performance.

• The control valve motor can also be checked.

• The following keys can be used if a keyboard and monitor are connected to the IntelliFlow microprocessor:

-D to enter the display monitor program, =/- keys to increase or decrease millisecond time.

-O to open the valve.

-C to close the valve.

52


These bench troubleshooting tests will evaluate the following:

1. Control valve motor integrity:

• Electric DC motor

• Transmission

• Internal electrical contacts Reverse voltage diodes

• Micro-switch limit switches

• External connections

• Stainless steel ball valve and seals

• Valve stem gumming (due to highly corrosive chemical products)

• Power head sealing (chemicals or water seeping)

IntelliFlow control unit integrity:

• The IntelliFlow has three different grounds:

1. M3 ground

2. Internal logic 5 Vdc ground

3. Aircraft ground

• General internal voltage checks (power blocks)

• Serial port integrity between intelliFlow control unit and M3

• Front panel connectors

• Front panel internal wiring

• Internal corrosion checks (due to water or chemical leakage)

53


• Digital power supply problems (check groundings and noise levels)

• Correct pulse input from turbine sensor (check amps)

• Logic input from pressure sensor (check logic inputs)

• Normal/bypass switch function (check internal wiring)

• Locate open or cold solder joints due to excessive vibration

• Microprocessor integrity, serial ports, DOC chip and OS, etc

• Troubleshooting internal board problems. See IntelliFlow schematics.

Note: Use external the external pulse generator for stable flow pulses, DMM, frequency counter and Oscilloscope.

54

APPENDIX B: FLYING FLAGMAN

TROUBLESHOOTING

Appendix B: Flying Flagman Troubleshooting

Basic IntelliFlow Aircraft Troubleshooting

In normal operation, apply aircraft power to the IntelliFlow control unit. Note the following:

• Wait 10 to 15 seconds for the IntelliFlow controller microprocessor to initialize. The microprocessor startup can be heard with a low beep if ambient noise is low.

• Wait and listen for the control valve motor rotation. The motor will rotate to fully open, rotate to fully closed, then finally reposition to 3/4 open.

If the IntelliFlow does not cycle:

1. Ensure that the override switch is in the normal position.

2. Ensure that there is power to the IntelliFlow controller and controller fuse.

3. Ensure that the pressure switch is normally open and working properly.

4. Check the fuse.

• Confirm that the aircraft power has been removed from the IntelliFlow controller.

• Remove the fuse from the IntelliFlow controller and inspect the fuse for signs of over current.

Note: Voltage sent to the Normal/bypass switch from the IntelliFlow controller does not pass through the 10 Amp fuse on the controller. This is a security feature in case the IntelliFlow controller malfunctions, allowing the control valve motor to rotate to the open position.

56


5. Check pressure switch.

• Remove the Aux switch I/O connector plug, where the pressure switch connects, from the IntelliFlow controller.

• Reset the system and check for normal operation. If the system responds, then there is a problem with the pressure switch.

If the valve functions properly, but the system still will not meter:

1. Manually spin meter and check for the system response.

2. Make sure the pressure switch is triggered or the system will not respond to the meter.

Note: If the pressure switch is stuck in the closed position, then the valve will not move.

57


If valve motor rotation is normal:

1. Check the voltage across the flow control sensor contacts if the motor does not rotate. The voltage should be logic 5 VDC.

2. Check the sensor cabling and/or sensor if the voltage across the sensor is 0 Vdc or less than 4 Vdc.

3. Disconnect the jumper across the pressure sensor if the operation in number 11 and 12 are normal.


5. Observe the touch screen flow status run screen by entering the following into the Flying Flagman:

DISPLAY, 7

Valve Position:


• 1550 = 3/4 open +/- 50

6. Connect and disconnect the jumber across the sensor and observe the status change from 44 to C4 and visa versa.

7. Toggle NORMAL/BYPASS to bypass the position. The motor will fully open.

Valve position numberStatus

58


8. Observe the touchscreen flow status Run Screen vavle position number.

Valve Position:


• 1550 = 3/4 open +/- 50

9. If the DISPLAY, 7 Run Screen is blank or the status does not change, the most probable causes are:

• Defective IntelliFlow control unit (serial port problems) and/or

• Incorrect GMU setup. See Chapter for further information about flow screens and correct setup parameters.

10. A transducer sensor can be connected to the cable that is normally connected to the flow turbine unit if a spare transducer is available. Pulses can be generated and observed on the CPU by passing or tapping an iron object over the pick-up point of the sensor. This can also be used as a general reference to the working condition of the IntelliFlow control unit and GMU. Simulated flow information can be observed in Display, 7 and Run Screens 9 and 00.

Note: These simulated pulses are not sufficient for accurate testing, but are sufficient for checking cables, IntelliFlow control unit I/O ports, interface between the IntelliFlow control unit and GMU and general display operation. Adjust for 200 Hz sqare wave, amplitude close to 150 mv, 0 offset, If a simple function generator is available. Connect the FG to the sensor connector to produce pulses and check dynamically the IntelliFlow system. See the next system, “IntelliFlow Bench System Testing” for additional instructions.

59



• Fuse is lower incorrect valve

• Aircraft IntelliFlow cable installation

• Aircraft IntelliFlow grounding connections

• Aircraft battery charging system, alternator/regulator/etc

• Aircraft battery state (common problem)

12. In addition to the following procedures, check the following:

• Check all wiring connections and terminal strips.

• Check that water or chemicals have not seeped into the IntelliFlow control unit or motor control unit. It is a good practice to have the water resistant canvas cover over the motor head if the aircraft is flown under adverse conditions.

• Check that the aircraft electrical system does not experience noisy or transit voltage problems. The IntelliFlow control unit can operate within a range of 20 to 32 Vdc. The voltage range must exceed 20 Vdc to modulate the motor and valve mechanism at the desire time rate.

Warning!

Do not install fuses greater than 10 Amps for the IntelliFlow control unit. Use the same type of fuse. A greater fuse valve will cause internal damage to the IntelliFlow control unit.

Note: This will avoid ground loops and faulty connections. Above all, avoid shorts to ground that will damage the IntelliFlow control unit and/or motor control unit. Check the IntelliFlow Control Unit grounding cable and grounding lugs.

60


• Check that the sensor unit and connector do not have water or chemicals inside.

• If the flow turbine unit that does not respond correctly or does not indicate pulses/flow on touchscreen, the problem is generally caused by a gumming of the turbine blades and internal bushings.

• If highly corrosive products are used, it is recommended that the valve stem be lubricated with a few drops of pneumatic turbine lubricating oil or, if not available, low viscosity lubricating oil every 20 to 30 hours of spray time. This will avoid gumming and/or chemical corrosion buildup around valve stem and/or gland sealing components. Penetrating oil can be applied if required. Use products

such as WD-40® or any quality penetrating oil before lubricating.

• The valve stem gland-retaining nut must not be tightened without due understanding of the sealing method of the valve stem. Any incorrect adjustment to the tension of the gland-retaining nut can adversely change the torque required to rotate the valve stem. This will cause the

Note: This can be avoided by washing the hopper/boom system thoroughly and methodically after spray sessions.

Note: If the flow turbine unit is totally bummed-up, the unit must be removed and cleaned on the bench. This requires disassembling the unit and reassembling it.

61


motor valve transmission and/or motor to over work, possibly causing damage.

Note: If the valve stem starts to gum-up, the motor valve will not respond to the IntelliFlow commands with the desired response. If the valve stem becomes too tight this can be detrimental to the motor valve transmission and motor, and cause excessive current through the power IC chip inside the IntelliFlow control unit.

62


IntelliFlow Bench System Troubleshooting

1. Confirm that the‘ bench power is removed from the IntelliFlow control unit.

2. Remove the fuse from the IntelliFlow control unit and inspect the fuse for signs of over current.

3. Connect the power cable and the control valve motor cable to the IntelliFlow control unit.

4. Connect the control valve motor to the control valve motor cable.


6. Toggle the flow sensor switch to the open position.

Note: It is mandatory to have a bench setup with known working cables and proven test units for successful. For example, IntelliFlow control unit, control valve motor, IntelliFlow cable set up and a GMU unit with all the cables and accessories. General test equipment is needed. If a simple function generator is available, adjust if for 200 Hz square wave, amplitude close to 150 mv, 0 offset. Use a toggle switch for sensor logic cable.

Note: The following procedures will vary depending on which unit is being tested.

Note: Voltage sent to the normal/bypass switch from the IntelliFlow control unit does not pass through a 10 Amp fuse on the control unit. This is a security feature in case the IntelliFlow control unit malfunctions, allowing the control valve motor to rotate to the open position.

63


7. Apply 28 Vdc bench power to the IntelliFlow control unit. Note the following:

• Wait 10 to 15 seconds for the IntelliFlow control unit microprocessor to initialize.

• Note the control valve motor rotation. The motor will rotate to fully open, then rotate to fully closed, then finally reposition to 3/4 open.

• If the control valve motor does not rotate:

1. Power to the IntelliFlow control unit must have the correct current requirement.

2. Control valve motor if under test.

3. IntelliFlow control unit if under test.

If the valve motor rotation is normal:

1. Remove the bench power from the IntelliFlow control unit.

2. Connect the aux switch I/O connector to the IntelliFlow control unit and GMU mainframe.

3. Confirm that the normal/bypass switch is in the normal position.

4. Apply bench power to the IntelliFlow control unit.

5. Wait 10 to 15 seconds for the IntelliFlow control unit microprocessor to initialize.

6. Note the control valve motor position. The motor will rotate to fully open, rotate to fully closed, then finally reposition to 3/4 open.

7. Check the voltage across the sensor toggle switch if the motor does not rotate (the voltage should be logic 5 Vdc).

8. Check the IntelliFlow control unit if the voltage across switch is 0 Vdc or less than 4 Vdc. This could be a possible internal logic problem.

Note: Microprocessor startup is a low beep.

64



1. Toggle the sensor switch to the closed position.

2. Power cycle the IntelliFlow control unit. The control valve motor should not rotate.

3. Check the IntelliFlow control unit if the motor rotates with the toggle switch is closed.



2. Toggle the sensor switch to the open position.

3. Observe the CDU flow status Run Screen by entering the following:

DISPLAY, 7

4. Toggle the sensor and observe the status change from 44 to C4 and visa versa.

5. Toggle the normal/bypass switch to the bypass position, motor fully open.

6. Observe the CDU flow status run screen valve position.


• 1550 = Valve 3/4 open +/-50

7. If the Display, 7 Run Screen is blank, the probable causes are a defective IntelliFlow control unit (serial port problems) and/or incorrect GMU setup.

Valve position numberStatus

65


8. Toggle the normal/bypass switch to the closed position.

9. Toggle the sensor switch to the closed position. If the toggle sensor switch is in the open position, the pulses, GPM/LPM, Area and Gal/Ac/Lit/Ha will not be displayed and will not change value on the touchscreen under the following simulated conditions.

10. Connect a GPS antenna to the GMU. Connect a differential source to the GMU if possible.

11. Connect a function generator, adjusted for 200 Hz square wave, amplitude close to 150 mv, 0 offset, to the cable that connects to the flow turbine unit sensor.

12. These generated pulses will provide a stable flow source for accurate bench tests. This dynamic data interchange of information between the IntelliFlow control unit and the GMU mainframe can be evaluated using the GMU-Display.

13. The test/simulate menu function allows the user to test the operation of the GMU system by using GPS position utlities to stimulate the flight pattern without the need to fly the airplane.

14. Set the GMU unit mainframe to simulate mode by entering:

SETUP, 7, 3

The following screen will be shown:

66


15. Check the screen to display the following:

16. Check the run screens to confirm that the simulator is running.

17. It is important to keep the field and flow parameters within a reasonable range of values to accommodate the flow pulses received from the function generator.

18. When the GMU is in the simulate run mode, the speed can be changed by using the up/down arrows on the touchscreen. Each key is equal to 1 mph +/-

19. An additional test can be made to the IntelliFlow control unit and control valve motor by using the 05-N2148 download cable and notebook.

• Connect the download cable to the IntelliFlow control unit.

• Connect the power cable to the IntelliFlow control unit.

• Connect the power/control table to the control valve motor.

• Toggle the bypass/normal switch to normal.

• Connect the opposite end of the download cable to the notebook (Com1).

• Us a PC communications application like Proccom Plus® or

Windows® HyperTerminal®, etc.

• Set the profile to Com1, 38400, 8, 1.

• Apply power to the IntelliFlow control unit.

67


• Observe the string in the terminal output after the IntelliFlow control unit initializes.

• Enter the lower case command to “open” and “close the the control valve motor in the terminal screen mode or chat mode.

• Indicate the time, in milliseconds, to move the control valve motor.

Example: open 50 open 135 open 2000 close 45 close 80 close 2000

• These open and close tests can be used to verify the IntelliFlow control unit and control valve motor internals for correct performance.

• The control valve motor can also be checked.

• The following keys can be used if a keyboard and monitor are connected to the IntelliFlow microprocessor:

-D to enter the display monitor program, =/- keys to increase or decrease millisecond time.

-O to open the valve.

-C to close the valve.

68


These bench troubleshooting tests will evaluate the following:

1. Control valve motor integrity:

• Electric DC motor

• Transmission

• Internal electrical contacts Reverse voltage diodes

• Micro-switch limit switches

• External connections

• Stainless steel ball valve and seals

• Valve stem gumming (due to highly corrosive chemical products)

• Power head sealing (chemicals or water seeping)

IntelliFlow control unit integrity:

• The IntelliFlow has three different grounds:

1. GMU ground

2. Internal logic 5 Vdc ground

3. Aircraft ground

• General internal voltage checks (power blocks)

• Serial port integrity between intelliFlow control unit and GMU

• Front panel connectors

• Front panel internal wiring

• Internal corrosion checks (due to water or chemical leakage)

69


• Digital power supply problems (check groundings and noise levels)

• Correct pulse input from turbine sensor (check amps)

• Logic input from pressure sensor (check logic inputs)

• Normal/bypass switch function (check internal wiring)

• Locate open or cold solder joints due to excessive vibration

• Microprocessor integrity, serial ports, DOC chip and OS, etc

• Troubleshooting internal board problems. See IntelliFlow schematics.

Note: Use external the external pulse generator for stable flow pulses, DMM, frequency counter and Oscilloscope.

70

APPENDIX C: SPAY OFF UNIT

Spray Off Interface/Specifications

Spray Off Interface Installation

Installation Diagrams

Appendix C: Spay Off Unit

SPRAY OFF INTERFACE SPECIFICATIONS

Table C-1 provides the spray off interface unit specifications.

Table C-1: Spray off interface unit specifications

Specification Description

Inverse voltage protection Yes

Over current and/or short circuit protection Yes

Operating voltage 11 to 60 VDC

Maximum working current 7 Amps

Maximum transit current 10 Amp

Nominal operating current range 0.1 to 6 Amps

72


SPRAY OFF INTERFACE INSTALLATION

Use the following steps for

1. The Spray Of Solid State Interface (SOSSI) unit can be installed in any dry and secure part of aircraft. The maximum distance from M3/GMU unit can be 15 feet owing to the signal control cable. The clutch/brake control cable is 15 feet long. The clutch/brake control cable should be connected as follows:

• White wire connected to clutch/brake circuit breaker (load side)

• Black wire connected to qualified aircraft frame ground

• Green wire connected to clutch/brake control solenoid (load side)

2. The SOSSI unit can be installed in aircraft cockpit visible to pilot. This method will provide visibility of red led; red led will glow when clutch/brake circuit is activated. (No Spray/Spray Off)

3. Do not install fuses greater than 8 Amps for the SOSSI unit. Use the correct fast blow type fuse. If a larger fuse value is used, this will cause internal damage because the current exceeds the unit current load capacity.


• Fuse is lower incorrect value.

• Check interface system cable installation for dead short or low resistance to aircraft ground.

• In order to find the following problems, disconnect ground return wire from the clutch/brake.

• In particular, check green wire to solenoid load side for short or low resistance to aircraft ground.

73


• Check wire from solenoid load side to the clutch/brake for short or low resistance to aircraft ground.

• Disconnect all wires to solenoid and check for internal resistance between contacts, coil and solenoid metal case.

• Disconnect both wires from the clutch/brake and check each wire for resistance to the clutch/brace metal case.

• Check diodes across the clutch/break and solenoid if used for short or low resistance. Diodes should read low resistance in one direction and high in the reverse direction.

74


Figure C-1 Shows the spray off automated control interface cable interconnections.

Figure C-1. Spray off automated control interface cableinterconnections

Brake Solenoid

Aircraft ground

Clutch/brake cable(05-F-2148)

C/B load side

180”

Diode 100 PIV 3 Amps(41-C-2600)

Aircraft ground

Brake stick switch

Cable color BLACK

Solenoid load side

10 Amp C/B

Aircraft BUSS 24 Volts

Brake control interface box(09-F-4000)

Cable color WHITE

Wires: white, black and green are 180” long Fuse holder

Cable part (05-F-2147)

Connect to GMU data port P3

Cable color GREEN

Connect to M3 aux IntelliFlow P4 plug

75


Note 1: The brake is on (no spray) when the red LED is on.

Note 2: GMU mainframe requires that pin A on connector P3 (data) be connected to pin S on P6 (Gp I/O). Use solid 28 Awg insulated wire. This will provide 12 VDC for the interface device.

Note3: The M3 mainframe requires Pin 4 of connector com. 1 have a 12 volt modification. See the “Modify the M3 for Variable Rate with IntelliFlow and “Spray Off” Controller” bulliten, released on January 8, 2007, for more information.

Warning!

Only use an 8 Amp fuse (fast blow).

76


INSTALLATION DIAGRAMS

Figure C-2 and C-3, on pages 81 and 83 provide the spray-off cable and cable interface/SO box.

IntelliFlow, Spray off, AUX, M3 Cable (Part number 05-F-2010)

Figure C-2. Spray-off cable

156”48”

24”

2

Label

2”

1”2

2 12 ft.

2”

Labels

P2 label

Connector10P-M, Bendix

PT06A-12-10P(SR)(32-A-3100)

detail A

Connector, 10-6P maleMS 3111F-10-6P

(32-A-1375)Detail C

P4 labelCable, 6C, 22AWG, shielded

(850-304)

Connector, 8P maleMS3111F-10-6P

(32-A-1375)detail C

Cable, 2C, 22AWG, shielded(18-C-0460)

Cable, 6C, 22AWG, Shielded

(850-304)

Connector, 10-6P maleMS3111F-10-6P

(32-A-1375)detail C

Connector 10-6P maleMS 3111F-10-6P

(32-A-1375)Detail C

77


Cable Assy, External, Spray OFF, M3 Cable (Part number 05-F-2015)

Figure C-3. Spray-off only cable

156”

15”

8 Pin male conn.,mates to VRC/COM1/M3 Heatshrink, ref

Connector, 8P male,282-8PG-321

(32-B-3554)

Label Note 1

Connector, 6P female,PW6F 10-6S(32-A-2885)

78

APPENDIX D:

PARTS LIST

Parts List

Parts List

Tables D1 to D8, on pages 82 to 85, provides the parts for the IntelliFlow system.

Table D-1: IntelliFlow motors

Part number

Description Quantity

09-C-1950 Motor/valve assembly with valve 1 in x 1x1.5 in x 1.5 in

One

09-C-2000 Motor/valve assembly with valve 1.5 in x 2 in x 2 in

One

09-C-2010 Motor/valve assembly with valve 2 in x 2 in x 2 in

One

09-C-2015 Motor/valve assembly with valve 1.5 in x 2 in x 2.5 in

One

09-C-2020 Motor/valve assembly with valve 2 in x 3 in x 3 in

One

Table D-2: IntelliFlow cable assembly

Part number


29-C-0424 Hose 1.5 in mil 6000 One 6 in to 20 in long

29-C-0432 Hose 2 in mil 6000 One 6 in to 20 in long

29-C-0440 Hose 2.5 in mil 6000 One 6 in to 20 in long

29-C-0445 Hose 3 in mil 6000 One 6 in to 20 in long

80


Table D-3: IntelliFlow hoses

Part number


26-F-6828 Hose clamp stainless steel max 2.25 in

8 or 12 pieces


8 or 12 pieces


8 or 12 pieces


8 or 12 pieces

Table D-4: Hose turbines

Part number


29-C-0296 Flow turbine S.S. 1 in x 1.5 in x 1.5 in 5-50 GPM

One

29-C-0305 Flow turbine S.S. 1.5 in x 2 in x 2in 15-180 GPM

One

29-C-0310 Flow turbine S.S. 2 in x 2 in x 2 in 30-380 GPM

One

29-C-0320 Flow turbine S.S. 1.5 in x 2.5 in x 2 in 5-180 GPM

One

29-C-0325 Flow turbine S.S. 2 in x 2.5 in x 2 in 30-380 GPM

One

29-C-0330 Flow turbine S.S. 2in x 3 in b 3 in 30 to 400 GPM

One

81

Parts List

Table D-5: Flow turbines

Part number


29-C-0296 Flow turbine S.S. 1 in x 1.5 in x 1.5 in 5-50 GPM

One

29-C-0305 Flow turbine S.S. 1.5 in x 2 in x 2in 15-180 GPM

One

29-C-0310 Flow turbine S.S. 2 in x 2 in x 2 in 30-380 GPM

One

29-C-0320 Flow turbine S.S. 1.5 in x 2.5 in x 2 in 5-180 GPM

One

29-C-0325 Flow turbine S.S. 2 in x 2.5 in x 2 in 30-380 GPM

One

29-C-0330 Flow turbine S.S. 2in x 3 in b 3 in 30 to 400 GPM

One

Table D-6: Miscellaneous parts

Part number


09-F-2000 IntelliFlow control unit One

80-B-1815 10 Amp breaker One

26-A-1725 Boom Pressure switch One

07-C-2000 Hardware kit One

05-N-2148 Cable, ext., IntelliFlow serial download (one per client)

One

82


Table D-7: Clutch/brake interface parts

Item Number

Part number Description Quantity

B1 09-F-4000 Spray off solid state interface unit One

C1 09-F-2147 Signal/control cable GMU to SoSSI unit

One

C2 05-F-2148 Clutch/brake control cable One

D1 41-C-2600 Diode 100 PIV 3 Amps One

Table D-8: Documentation

Hemisphere GPS part number


875-0166 Warranty page One

875-0180 IntelliFlow user guide One

83

www.hemispheregps.come-mail: [email protected]

Documents

IntelliFlow - AGROTECagrotec.etc.br/downloads/IntelliFlow_User_Guide_8750180000_RevA1.… · Hemisphere GPS and the Hemisphere GPS logo, Satloc and the Satloc logo, Mapstar, Air