Manifold - Field Sprayer · 2019-10-01 · Pressure sensor . A pressure sensor determines the pressure in the valve. The determined pressure is transmitted to a computer. Depending

Installation and operating instructions

Manifold - Field Sprayer

Version: V2.20191001

302358-02-EN Read and follow these instructions. Keep these instructions in a safe place for later reference. Please note that there might be a more recent version of these instructions on the homepage.

Company details

Installation and operating instructions Product: Manifold - Field Sprayer Document number: 302358-02-EN As of software version: Original instructions Original language: German

Müller-Elektronik GmbH Franz-Kleine-Straße 18 33154 Salzkotten Germany Phone: ++49 (0) 5258 / 9834 - 0 Fax: ++49 (0) 5258 / 9834 - 90 Email: [email protected] Homepage: http://www.mueller-elektronik.de

Document

Copyright ©

Table of contents

302358-02-EN V2.20191001 3

Table of contents

1 For your safety 5 1.1 Basic safety instructions 5 1.2 Intended use 5

2 About these Operating Instructions 6 2.1 Target group of these Operating Instructions 6 2.2 Layout of references 6 2.3 Layout of operating instructions 6

3 Product description 7 3.1 Purpose of the manifold 7 3.2 Versions of the manifold 7 3.3 Structure of the manifold 7 3.3.1 Unit for controlling the application rate 7

Connection for the flow meter 8 Hand valve 8 Control valve with return line 1 8 Filter the sieve insert 8 Safety valve 8 Electric bypass valve 8 Return line 2 8 Proportional control valve 9

3.3.2 Unit for section control 9 Connection for a pressure sensor or a manometer 9 Section valves 10 Section connections 10 Connection for the flow meter 10

3.4 Additional components 10 3.4.1 Flow meter 10 3.4.2 Pressure sensor 10 3.4.3 Manometer 11

4 Installation 12 4.1 Selecting the mounting position 12 4.2 Constructing a mounting bracket 12 4.3 Connecting hoses to the manifold 12 4.3.1 Connecting the pump 12 4.3.2 Connecting return lines 12 4.3.3 Connecting the hand valve 12 4.3.4 Connecting sections 13 4.3.5 Replacing grommets 13 4.4 Connecting the manometer 14 4.5 Connecting the manifold to power supply 14 4.6 Connecting the manifold to the junction box 14 4.6.1 Connecting the actuators and sensors to the junction box 14

Table of contents

4 V2.20191001 302358-02-EN

4.6.2 Inserting the cable core into a terminal 15 4.6.3 Connecting the valve to the junction box 16

5 Adjusting the manifold 18 5.1 Configuring the manifold 18 5.2 Performing the start-up of the manifold 18 5.2.1 Start-up with manometer or pressure sensor 18

Closing the control valve 19 5.2.2 Start-up without manometer or pressure sensor 19

6 Maintenance and technical data 20 6.1 Maintenance 20 6.2 Preparing for winter 20 6.3 Technical specifications 20

7 Overview and spare parts lists 21 7.1 Unit for regulating the application rate up to 160l/min 21 7.2 Unit for regulating the application rate up to 250l/min 23 7.3 Unit for section control 25

For your safety

Basic safety instructions 1

302358-02-EN V2.20191001 5

For your safety

Basic safety instructions Please read the following safety instructions carefully before using the product for the first time. ▪ Do not make any unauthorized modifications to the product. Unauthorized modifications or use

may impair safety and reduce the service life or operability of the unit. Modifications are considered unauthorized if they are not described in the product documentation.

▪ Never remove any safety mechanisms or stickers from the product. ▪ Observe all applicable regulations on accident prevention. ▪ Wear required protective equipment while working with hazardous spray agents.

Intended use The manifold is intended exclusively for use in agriculture as well as in wine-growing, fruit-cultivating, and hop-growing operations. The manufacturer cannot be held responsible for any installation or use of the system that deviates from or exceeds the scope of intended use.

The manufacturer cannot be held liable for any personal injury or property damage resulting from such non-compliance. All risk arising from improper use lies with the user.

Intended use also includes compliance with the conditions for operation and repairs prescribed by the manufacturer.

All applicable accident prevention regulations and all other generally recognized safety, industrial, and medical standards as well as all road traffic laws must be observed. Any unauthorized modifications made to the equipment will void the manufacturer's warranty.

1

1.1

1.2

2 About these Operating Instructions

Target group of these Operating Instructions

6 V2.20191001 302358-02-EN

About these Operating Instructions

Target group of these Operating Instructions This manual is for specialist staff, which assembles and maintains the described manifold.

The specialist staff must have deep-seated knowledge in the following areas: ▪ Installation of agricultural machines ▪ Operating mode and design of field sprayers ▪ Electrics and electronics

Layout of references If any references are given in these Operating Instructions, they appear as:

Example of a reference: [➙ 6]

References can be identified by their square brackets and an arrow. The number following the arrow shows you on what page the section starts where you can find further information.

Layout of operating instructions The operating instructions explain step by step how you can perform certain operations with the product.

We use the following symbols throughout these Operating Instructions to identify different operating instructions:

Type of depiction Meaning

1.

2.

Actions that must be performed in succession.

⇨ Result of the action.

This will happen when you perform an action.

⇨ Result of an operating instruction.

This will happen when you have completed all steps.

Requirements.

In the event that any requirements have been specified, these must be met before an action can be performed.

2

2.1

2.2

2.3

Product description

Purpose of the manifold 3

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Product description

Purpose of the manifold The manifold is for application rate controlling and section controlling by a computer.

Versions of the manifold The manifold is available in two versions by Müller-Elektronik. Both manifolds work without constant pressure. ▪ Manifold – Flow up to 160l/min

Item number: 31235805 ▪ Manifold – Flow up to 250l/min

Item number: 31235803

Structure of the manifold The entire manifold consists of two units: ▪ Unit for controlling the application rate ▪ Unit for section control

Both units are describes separately in the next sections

Unit for controlling the application rate

Example: Unit for controlling the application rate – Manifold 160 l/min

Connection for the flow meter Safety valve

Hand valve Electric bypass valve

Control valve with return line 1 Return line 2

Filter the sieve insert Proportional control valve with pump input and return line 3

3

3.1

3.2

3.3

3.3.1

3 Product description

Structure of the manifold

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Connection for the flow meter You can connect the flow meter to this input.

Hand valve You can connect the following components to the hand valve: ▪ Optionally, you can connect a further return line if the pump speed is very high and the

application rate is low. This return line flow leads the spray agent back to the tank bottom or to a second stirrer.

▪ Optionally, you can also connect a filter with sieve insert.

Control valve with return line 1 The control valve regulates the amount of spray agent that continues to flow in the direction of the section valves. Excess spray agent is returned to the tank via return line 1.

The job computer controls the operation of the control valve on the basis of the measured and the planned application rate.

Filter the sieve insert

CAUTION Risk of poisoning or caustic burns due to residues of spray agents When you open the valve of the filter with sieve insert:

◦ Make sure that you are not hit by spray agent residue.

◦ Wear protective equipment in accordance with the specifications of the spray agent manufacturer.

If you open the valve of the filter with sieve insert, the internal filter will be cleaned.

Safety valve The safety valve is used to determine the maximum pressure in the manifold. The safety valve returns the spray agent to the tank via return line 2. The safety valve is a spring-loaded valve that is activated when the pressure is higher than the resistance of the spring.

Electric bypass valve When the job computer stops spraying, the electric bypass valve returns excess spraying agent to the tank via return line 2.

Return line 2 Return line 2 is a return line from the electric bypass valve and from the safety valve to the tank.

Product description

Structure of the manifold 3

302358-02-EN V2.20191001 9

Proportional control valve

Output for the unit for controlling the application rate

Pump input

Return line 3

If the pump has a flow rate higher than 160 l/min, a maximum flow can be set. For this purpose you can optionally connect a proportional control valve. The proportional control valve is a manual valve that allows you to set a maximum flow. The proportional control valve has the following inputs and outputs: ▪ Input for the unit for controlling the application rate

Here you can connect the unit for controlling the application rate. ▪ Pump input

You can connect the pump to this input. ▪ Return line 3

Return line 3 is a return line from the proportional control valve to the tank.

Unit for section control


Connection for a pressure sensor or a manometer

Section connections

Section valves Connection for the flow meter

Connection for a pressure sensor or a manometer A pressure sensor or a manometer can be connected to this output.

3.3.2

3 Product description

Additional components

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Section valves Section valves control the flow to the nozzles. Five motorized section valves are mounted as standard on the manifold. However, the number of section valves can be increased.

The section valves are opened and closed by an electric engine. The direction in which the electric engine rotates when current flows determines whether a section is closed or opened. Therefore, you must try for yourself which direction is the correct one. If the direction is not correct, you must change the assignment of the terminals in the junction box. [➙ 16]

Section connections Each section valve must be connected to a junction box. You will find the correct assignment either directly on the board, on a sticker in the junction box or in the pin-out diagram.

Connection for the flow meter You can connect the flow meter to this input.

Additional components

Flow meter A flow meter determines the amount of spray agent flowing in one direction.

On the manifold, the flow meter determines the quantity of spray agent flowing in the direction of the sections.

The determined flow rate is transmitted to a computer. The computer can use the flow rate to calculate whether to open or close the control valve in order to achieve the desired application rate.

The flow meter is used in most systems to calculate the current application rate. In some systems the flow meter can be replaced by a pressure sensor.

The following flow meters can be connected to the manifold: ▪ Flow meter, Low-Flow NW 20

Flow: 8-140 l/min Item number: 30244510

▪ Flow meter, Low-Flow NW 25 Flow: 14-220l/min Item number: 30244710

▪ Flow meter, Polmac 1'' Turbo-Flow Flow: 6-140 l/min Item number: 30244910

Pressure sensor A pressure sensor determines the pressure in the valve.

The determined pressure is transmitted to a computer. Depending on the computer, the pressure can be displayed or used to control the application rate. For example, if you are using the SPRAYDOS product, the pressure may be displayed on the display.

3.4

3.4.1

3.4.2

Product description

Additional components 3

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Manometer A manometer indicates the pressure during work.

You can use a manometer to adjust the safety valve and the electrical bypass valve. A manometer is optional and not included.

3.4.3

4 Installation

Selecting the mounting position

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Installation

Selecting the mounting position When selecting the mounting position, you must consider the following: ▪ The hose connections to the boom must be kept as short as possible. ▪ The section control unit can be mounted separately from the application rate control unit. Both

units can be mounted side by side or on top of each other.

Recommended places of mounting: ▪ For mounted sprayers (three-point hitch)

– in front of or behind the tank

▪ For integrated sprayers (UNIMOG/system tractor)

– on the tank

▪ For trailed sprayers

– on or behind the tank

Constructing a mounting bracket To mount the manifold, you need a mounting bracket with which you can mount the manifold on the field sprayer. You must construct this mounting bracket yourself or order its construction.

Connecting hoses to the manifold

NOTICE Restriction of the control range by back pressure When you connect the hoses to the manifold, unnecessary angles and fittings can build up back pressure. When connecting the hoses:

◦ Avoid unnecessary angles and screw connections.

Connecting the pump

1. Connect the pump to the pump input with a hose.

Connecting return lines

1. Connect return line 1 with a hose to the large-volume stirrer.

2. If the field sprayer has a mechanical stirrer, lead the hose to the tank bottom. This will prevent foam formation. Foam can reduce the accuracy of the control.

3. Run a hose from return line 2 to the tank bottom.

Connecting the hand valve

The rotational speed of the pump is very high.

4

4.1

4.2

4.3

4.3.1 Procedure

4.3.2 Procedure

4.3.3 Procedure

Installation

Connecting hoses to the manifold 4

302358-02-EN V2.20191001 13

The application rate is low.

1. Connect a hose to the hand valve to direct the spray agent directly to the tank bottom or to a second stirrer.

2. Optionally, you can also connect the filter with sieve insert to the hand valve.

Connecting sections A section is a group of nozzles adjacent to the boom and connected by a common hose. All nozzles of a section are supplied with spray agent from a common section valve.

The number of boom sections is limited by the following factors: ▪ Number of section valves on the field sprayer manifold. ▪ Number of section valves that a computer can control.

You can decide for yourself how many sections your boom should consist of and how many nozzles should be connected to one section.

The extreme left section valve must be connected to all nozzles of the outer left boom section by a hose.

1. Run a hose from the outer left section to the outer left section valve.

2. Connect the hose to the outer left section valve.

3. Run a hose from the second section from the left to the second section valve.

4. Connect the hose to the second section valve.

5. Repeat the steps for all other hoses of the sections.

Replacing grommets You can replace the grommets on which the hoses are mounted.

Metal lock Seal

Grommet

1. Lift the metal lock of the grommet and pull the metal lock out of the openings.

2. Pull the grommet out of the metal lock.

3. Pull the grommet out of the hose.

4. Put the hose onto a new grommet.

4.3.4

Procedure

4.3.5

Procedure

4 Installation

Connecting the manometer

14 V2.20191001 302358-02-EN

5. Put a seal on the new grommet.

6. Insert the new grommet into the manifold.

7. Insert a metal lock from above so that the grommet is locked against falling out.

Connecting the manometer When connecting a manometer, mount the manometer outside the tractor cab, close to the manifold and so that you can see it from the tractor cab.

Connecting the manifold to power supply Connect the battery connector cable directly to the pins of the battery or starter motor. The junction box is fused with 25A.

Signal name Colour of the cable core

+12 VE brown

Ground blue

Connecting the manifold to the junction box This section shows you an example of how to connect the manifold to the junction box. You will find the correct assignment either directly on the board, on a sticker in the junction box or in the pin-out diagram.

Connecting the actuators and sensors to the junction box Actuators and sensors are connected to the junction box using two- or three-core cables. The colour of the sheath around the core allows you to recognize the polarity of a cable core and the socket to which it should be connected.

Connection of sensors

Signal name Terminal in the junction box

Colour of the cable core in the standard cable provided by Müller-Elektronik

+12 VE 12VE Brown (br )

Signal Sig Green (gn )

Ground, 0VE, GNDE 0VE White (ws )

The sticker in the junction box shows how the actuators should be connected. The colours of the cable cores are different than for sensors.

The terminal to which you must connect the cable core depends on the respective implement and on the type of sensor or actuator.

The information about the color of the cable core is on the board. The following table contains an overview of the possible cable colors provided by Müller Elektronik and the abbreviations used.

4.4

4.5

4.6

4.6.1

Installation

Connecting the manifold to the junction box 4

302358-02-EN V2.20191001 15

Colour of the cable core Abbreviation on the board

Blue bl

Brown br

Green gn

Black sw

White ws

NOTICE Risk of short-circuit When exchanging the polarity of cable cores, machine sensors can be damaged by a short-circuit.

◦ Pay attention to the polarity of the cable cores and the terminals.

The junction box is not powered.

There is no voltage on the components to be connected.

1. Remove the cable coating so that all cable cores are exposed.

2. Insert the cable to the end of the coat. There should only be cable cores inside the junction box. The cable coating must end at the junction box casing. This is the only way to ensure that you have enough space in the junction box to be able to guide all of the cable cores to the terminals.

3. Remove the cable coating of the cable cores ca. 1 cm from the end of the cable core.

4. CAUTION! Pay attention to the proper polarity of the cable cores and the terminals.

5. Connect the cable cores to the terminals. To do so, use the information on the lid of the junction box, on the relay circuit board and in the pin-out diagram.

6. With screw terminals, use wire end sleeves. Wire end sleeves may not be used with spring-loaded terminal blocks.

7. Close the screw connections of the junction box. After screwing them shut, the glands should be sealed.

8. Close unused openings in the casing of the junction box with blind caps.

Inserting the cable core into a terminal Each terminal consists of two openings: ▪ The upper opening of the terminal opens the lower opening. ▪ The bottom opening of the terminal serves to insert and clamp one cable core.

You have prepared a small flat screwdriver that fits the upper opening of the terminal. You only need this screwdriver if there are no wire end sleeves on the cable cores.

You have cut the cable to the proper length and have exposed the cable cores according to the instructions, or you have a finished cable from Müller Elektronik.

The tractor engine is switched off.

The junction box is not powered.

Procedure

4.6.2

Procedure

4 Installation

Connecting the manifold to the junction box

16 V2.20191001 302358-02-EN

There is no voltage on the components to be connected.

1. Find the proper connectors for the cable cores to be connected. To do so, use the information on the lid of the junction box, on the relay circuit board and in the pin-out diagram.

2. Insert the cable core into the opening in the lower part of the terminal. If you are not using wire end sleeves, you first have to use the screwdriver.

⇨ The cable core will be held by the terminal.

⇨ You have clamped the cable core.

Connecting the valve to the junction box You must connect the following valves to the junction box: ▪ Electric bypass valve ▪ Control valve ▪ All section valves

To connect, proceed as follows. Note that the assignment of the terminals may differ. The correct assignment of the terminals can be found on the circuit board, on a sticker in the cover of the junction box or on a pin-out diagram.

Connection in junction box

Control valve connection Cabel core: blue, contact: -

Section connections Cabel core: brown, contact: -

Control valve connection Cabel core: brown, contact +

Section connections Cabel core: blue, contact: +

Electric bypass valve connection Cabel core: brown, contact: -

Flow meter, manometer and pressure sensor connection

Electric bypass valve connection Cabel core: blue, contact: +

This is how you must proceed when connecting valves to the junction box.

You have the correct assignment of the terminals.

1. Push the seals onto the connectors.

2. Connect the control valve and the electrical bypass valve to the correct terminals in the junction box using one connector cable each.

3. Connect the sections to the junction box using the connector cables. Start with section 1.

4.6.3

Procedure

Installation

Connecting the manifold to the junction box 4

302358-02-EN V2.20191001 17

If you use additional components, you must also connect them to the junction box with the correct assignment.

Signal name Contact Colour of the cable core

Signal Sig green

12V 12V brown

Ground 0V white

5 Adjusting the manifold

Configuring the manifold

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Adjusting the manifold

Configuring the manifold Depending on which system you connect the manifold to, you must proceed differently when configuring the manifold. Read the instructions of the computers to learn the exact procedures.

Regardless of the system, you usually have to configure the following settings: ▪ Number of sections ▪ Regulation factor ▪ Manifold type

Performing the start-up of the manifold

Start-up with manometer or pressure sensor

You have mounted the manifold correctly.

You have connected a manometer or a pressure sensor to the manifold.

1. - Open the proportional control valve completely.

2. - Close the safety valve. ⇨ You have prepared the valves for the initial start-up.

3. Depending on which system you are using: Switch on the voltage at the junction box or start the terminal.

4. - Close the control valve. [➙ 19]

5. Start the tractor.

6. Engage the PTO shaft.

7. Start spraying.

8. Set the tractor engine to the operating speed. ⇨ You can now set the valves to the optimum pressure.

9. - Close the proportional control valve until the manometer indicates about 3 bar above the maximum spray pressure.

10. - Open the safety valve until the pressure is still 2.5 bar above the maximum spray pressure.

⇨ You now only need the control valve to set the application rate.

5

5.1

5.2

5.2.1 Procedure

Adjusting the manifold

Performing the start-up of the manifold 5

302358-02-EN V2.20191001 19

Closing the control valve If you want to close the control valve, you must proceed differently depending on the system. For more information, refer to the appropriate operating instructions.

If using SPRAYDOS, SPRAYLIGHT, UNI-Control S, or SPRAY-Control S:

1. - Set the “Manual/Automatic” switch to “Manual”.

2. - Press the button “+/-” to “+” and hold until the servomotor switches off automatically.

If you are using a terminal:

1. - Switch to the manual mode of application.

2. - Press until the servomotor switches off automatically.

Start-up without manometer or pressure sensor

If you do not use a manometer or pressure sensor, you must adjust the pressure by trial and error.

If, while spraying, you notice that the pressure in the manifold is not correct, you can make the following settings to regulate the pressure.

▪ - Open the proportional control valve until the correct pressure is reached.

▪ - Close the safety valve until the correct pressure is reached.

Always try to adjust the pressure by opening the proportional control valve before closing the safety valve.

Procedure 1

Procedure 2

5.2.2 Procedure

6 Maintenance and technical data

Maintenance

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Maintenance and technical data

Maintenance The electrical system is maintenance-free.

To keep the manifold clean, rinse the manifold with clear water after each use.

Preparing for winter In order not to damage the manifold in winter, you must carry out the following work:

1. Fill the tank with approx. 10 litres of antifreeze diluted 1:1 with water.

2. Switch on the field sprayer.

3. Wait until antifreeze runs out of all nozzles.

4. Switch off the field sprayer.

5. Leave the antifreeze in the system in winter.

Technical specifications

Section valves Motorized

Control valve Motorized

Electric bypass valve Motorized

Safety valve Spring loaded, manual

Proportional control valve Proportional, manual

Constant pressure function Is taken over by the computer

Control of the application rate Is taken over by the computer

Maximum pressure 12 bar

Maximum deviation from the set application rate +/-3%

Power supply 11 V - 16 V DC

Current consumption Approx. 3A (with 5 sections)

6

6.1

6.2

Procedure

6.3

Overview and spare parts lists

Unit for regulating the application rate up to 160l/min 7

302358-02-EN V2.20191001 21


Unit for regulating the application rate up to 160l/min

32895417 incl. O-rings

32895411 grommet 12mm 32895410 grommet 16mm 32895412 grommet 19mm incl. O-ring

32895421 incl. O-ring

32895408 flange 32895501 O-ring


Figure Item number Name

31235801 Arag connector cable 3.5m 2x

O-ring 1“

Cap nut 1“

Grommet straight 1“ 25mm

Grommet angled 1” 25mm

Grommet 19mm

Flow conditioner DN20

32895419

32895420

Cap nut 1“

Cap nut ¼“

7

7.1

7 Overview and spare parts lists


22 V2.20191001 302358-02-EN


32895415

32895425

337714

33771500

Grommet straight 1" 25mm

Grommet straight 1 ¼“ 32mm

O-ring 1“

O-ring ¼“

32895416

32895426

337714

33771500

Grommet angled 1” 25mm

Grommet angled 1 ¼“ 32mm

O-ring 1“

O-ring 1 ¼“

32895412 Grommet, 19mm incl. O-ring

32880016 Flow conditioner DN20

32895401

32895402

32895501

Flange 1” section side

Flange ¼“ section side

O-ring

32895408

32895406

32895501

Flange 1” on control side

Flange 1 ¼“ on control side

O-ring

32895400 Connection flange for pressure sensor

31236100 Proportional control valve

31236115 Control valve up to 160l/min

31236120 Electric bypass valve up to 160l/min

32895501 O-ring for sections, flange

31236010 Filter the sieve insert


Unit for regulating the application rate up to 250l/min 7

302358-02-EN V2.20191001 23


328969 Sieve insert

312359 Hand valve

32895504

32895503

Connector cable 1.3m






32895411 grommet 12mm 32895410 grommet 16mm 32895412 grommet 19mm incl. O-ring


32895406 flange 32895501 O-ring

7.2

7 Overview and spare parts lists


24 V2.20191001 302358-02-EN


31235808 Flange ¼“

O-ring 1 ¼“

Cap nut 1 ¼“


Grommet angled 1 ½“ 25mm

32895402

32895501

Flange 1 ¼“ section side

O-ring

32895406

32895501

Flange 1 ¼“ on control side

O-ring

32895420 Cap nut 1 ¼“

32895425

32895427

33771500



O-ring

32895426

32895428

33771500

Grommet angled 1 ¼“ 32mm

Grommet angled ½“ 32mm

O-ring

32895400 Connection flange for pressure sensor

31236116 Control valve up to 250l/min

31236121 Electric bypass valve up to 250l/min


31236010 Filter the sieve insert

328969 Sieve insert


Unit for section control 7

302358-02-EN V2.20191001 25


312359 Hand valve

32895504

32895503





31235802 O-ring 1 ¼“

Cap nut 1 ¼“


Grommet bent 1 ½“ 25mm

31236110 Section valve grommet 12mm

32895411

32895410

32895412

Grommet section valve 12mm




7.3

Documents

Manifold - Field Sprayer · 2019-10-01 · Pressure sensor . A pressure sensor determines the pressure in the valve. The determined pressure is transmitted to a computer. Depending