Y1. Troubleshooting / Service Guide for SureFire PWM Liquid Application Systems John Deere GS & GS Rate Controller

Transcription

1 Troublehooting / Service Guide for PWM Liquid Application John Dee GS & GS Rate Controller Alway verify the controller etting. See the cenhot in Section F of the y manual. The pump won t run. Electric Pump EPD flahing 4 time 1. nd the EPD (electric pump driver) hown above. Should have a eady blinking light in the middle when pump hould be off. If Statu LED i flahing 4 time, then pauing, EPD ha tripped due to low voltage condition. Unplug the Power pply to the EPD to et. If condition peri, check Power pply cable from battery to EPD to inu olid connection and good electrical path. (The hould be volt at the point whe the EPD connect to the battery power harne, when teed under load. Thi voltage may how up when the i no load, but the harneing may not be good enough to deliver volt under load.) No Light on EPD 1. The hould be a eady blinking light in the middle of the EPD. If no light i ON, check the 40-amp fue in the EPD harne near the battery. Ue a voltmeter to verify that the i volt at the Power pply connector that plug into the EPD. Will pump run? 1. Connect the two large connector that a plugged into the bottom of the EPD to each other (bypa the module and upply 12 volt dictly to pump). 2. Do the pump run? If not, check the 40 amp fue in the EPD harne near the tractor battery. Inpect harnee and connection. If 2 pump y, plug pump in by thelve to check both. Electric pump only run with 12 volt dict from battery 1. Connect pump and power harne back to EPD. 2. Go to Diagnoic, Section Te to inveigate thi iue. 3. In Section Te, hold down + button for a few econd. A ingle tap of thi button produce a very mall change in ignal to the valve, o you mu hold it. 4. Rove PWM valve connector at EPD and check voltage. You will need 4-12 volt to turn pump on. 5. If 4-12 volt i not pent, check harnee and view control valve type etup. 6. Go back to the 16-pin connector that plug into the Pump harne. Check voltage between pin 3 & Go back to the 37 pin connector at the John Dee Rate Controller. Check voltage between pin 15 & 16, hould be between 6-12 volt while in ection te after holding + button. 8. If you cannot get voltage at pin 15 & 16, contact your John Dee dealer for further aiance. For mo complete y information ee the manual for your y. Manual can be een and downloaded at The manual alo contain wiring harne diagram. Troublehooting/Service Guide for PWM Liquid -John Dee 1

2 Hydraulic Pump Will Not Turn Turn hydraulic off, go to the PWM valve and ue the manual override (d knob) on top of the electric coil to manually open the valve (Manual Override UP = valve fully open). The may be dirt in he that need to be cleaned out befo you can turn and raie the override. Turn hydraulic on at a low flow only a the valve i 100% open. If pump doe not turn, try hydraulic lever in oppoite diction. Doe the pump turn? If it turn, your probl i electric / electronic. If the pump ill doe not turn, you have a hydraulic probl. Electric / Electronic Probl Hydraulic Probl 1. Cloe manual override (lock down) 1. Leave the manual override open on the valve. 4. In Section Te, hold down + button for a few econd. A ingle tap of thi button produce a very mall change in ignal to the valve, o you mu hold it. 5. Take a metal object and hold it next to the coil. If the coil i working, you will feel the magnetic pull. 6. If no magnetic force i felt, diconnect the PWM valve connector and check voltage. You will need 6-12 volt to get hydraulic valve to open. 3. Verify hydraulic a on. 2. Check the hoe routing. The P port on the valve hould hook to pu. The T port i the turn that hould flow back to the tractor. 3. Try hoe in a diffent hydraulic mote. Inpect hydraulic connector for damage or riction. Hydraulic Manual Override Down - Normal Operation Up - Override, valve 100% open 7. If 6-12 volt i not pent, check harnee and view control valve type etup. 2. Go to Diagnoic, Section Te to inveigate thi iue. 8. Go back to the 16-pin connector that plug into the Pump harne. Check voltage between pin 3 & Go back to the 37-pin connector at the John Dee Rate Controller. Check voltage between pin 15 & 16, hould be between 6-12 volt while in ection te after holding + button. 10. If you cannot get voltage at pin 15 & 16, contact your John Dee dealer for further aiance. 11. You can move the electromagnetic olenoid with proportional valve to ee if the valve move when a PWM ignal i ent to it. The Section Te i a very ueful diagnoic tool in ervicing the John Dee y. It i a good way to prime the pump initially. While running the Section Te, it i helpful to to the cen to ee Pu and gal/min. It can be helpful to go the Reading > Delivery to ee information on the flowmeter operation and the PWM Duty Cycle. Te > Nozzle Flow Check i a good cen to try a Speed and Target Rate to ee if it will lock on to a rate. When teing with water, the pu will be a lot le than it will be when uing a fertilizer product. Troublehooting/Service Guide for PWM Liquid -John Dee 2

3 Application Rate Fluctuate r, you need to determine if the fluctuation i caued by the controller ending fluctuating ignal to the valve or becaue of omething ele. 1. Inpect & clean pump inlet rainer. Strange flow rate fluctuation a very often due to an obruction to the pump inlet. Inpect plumbing from tank to pump. OR 1. Go to Section Te a hown in Initial Operation, Section F. 2. Turn the y on. Watch the flow in GPM on the 1,2,3 cen. 3. I the flow eady within a very mall range? For example, a fluctuation from 12.3 to 12.6 GPM would be conided normal. A fluctuation from GPM i a probl. If only a mall normal fluctuation i een in ection te, kip ep 4-8 and proceed to Application Rate Fluctuate in eld.. below. 4. If the i a large fluctuation, oberve the y flow. I the dicharge a eady am; a the flow indicator ball floating eady? 5. If viually the flow i eady, but the diplay port a fluctuation in GPM, inpect the flowmeter. See ection B of manual for flowmeter information. Check connection between tank and pump. A looe connection may not how up a a leak, but it can be a place whe air can be ucked in. Air in the y will caue erratic flowmeter operation. 6. If viually the flow i uneady, the flowmeter i working corctly porting a flow probl. I the pump turning eady or urging? 7. If the pump i turning eady, the hydraulic circuit i functioning corctly. Look for any type of obruction in the pump inlet. Clean the rainer. If continually plugging the rainer inveigate fertilizer quality and neceary rainer ize. 8. If the pump peed i urging, the i a hydraulic probl. Application Rate fluctuate in field, but flow in Section Te mode i able. Thi probl indicate the valve calibration need changed. The y i urging becaue the Rate Controller i moving the hydraulic valve too much. 1. Go to Setup - - PWM Setup. 2. Change the Valve Calibration by ducing the valve peed (fir two digit). For example, duce the number for 4012 to 3012, which change valve peed from 40 to 30. (After ducing the fir two digit, you might try incaing the econd two digit from 12 to 23. Thi will alo help to eady the valve operation.) Application Rate i low to get to the Target Rate 1. You may need to incae the valve calibration. Go to Setup - - PWM Setup. 2. Change the Valve Calibration by incaing the valve peed (fir two digit). For example, incae the number from 3012 to 4012, which change valve peed from 30 to 40. If thi number i et too high, the rate will ocillate a you a going acro the field. 3. If y i too low to get to the Target Rate when arting, go to Setup - PWM Setup. Raie the Low Limit. Thi will art the pump at a faer peed when it initially turn on. (Thi number et the low limit of your pump, o if it i et too high your pump may not be able to low down enough at low peed/low rate etting or with ome ection turned off.) 4. Optional Method 1 to get to Target Rate faer: (Caution: You can only ue thi method if you have Electric Section Valve.) Go to Setup -. Set Control Valve Type to PWM. Thi leave the pump running at the la peed when product application i opped. Under PWM Setting check the Pump Enable Checkbox. With the ection valve cloed and the pump running, thi can build up too much pu in the y at time. To duce thi pu, open the Recirculation Regulation Valve lightly. Since thi will caue continuou circulation, it will duce the maximum output to the row that i attainable and the pump will run at a higher peed all the time. 5. Optional Method 2 to get to Target Rate faer: Ue the John Dee Rate Controller Flow Return featu. Thi will involve adding an additional electric valve and plumbing to turn flow to the tank when product application i opped. It alo qui a harne with Flow Return connection. On the Setup - cen, check the Flow Return box. In Setup -, the Control Valve Type i et to PWM. Under PWM Setting check the Pump Enable Checkbox. With the Control Valve Type et to PWM, the pump continue to run at the la peed it wa running when product application wa opped. Flow at thi time i turned to the tank. When product application i umed, flow i diverted from the tank back to the row. Troublehooting/Service Guide for PWM Liquid -John Dee 3

4 No Flow hown on GS2/GS3 but liquid i being pumped Flowmeter Tap Te 1. Unplug the flowmeter. With voltmeter, check for 12 volt between pin B & C of flowmeter connector (on main harne PN Y2). If 12 volt not pent, inpect wiring harne and troublehoot all connection per chatic (ee Section D). 2. If 12 volt i pent, then conduct a tap te. Go to etup and change the flow cal to 10. Have a econd peron watch GPM on the 1,2,3 cen while other peron tap (ue a hort piece of wi or a paper clip) between pin A & C of flowmeter connector (on Y2 harne). A flow value hould how up indicating the wiring i not damaged. (If alone, note or et a volume counter to 0 and check for incaed volume after tapping.) 3. If GS2/GS3 ponded to the tap te, your wiring to that point i good. If ill not fixed, inpect adapter harne and te continuity per chatic (ee Section D). 4. Replace flowmeter. 5. Change Flow Cal back to appropriate Flow Cal when finihed with Tap Te. 6. ha a Speed/Flow Simulator (PN ) that can be ued to confirm if the wiring i good between the flowmeter and controller. Section Valve() will not move 1. Go to Diagnoic, Section Te to inveigate thi iue. 2. In Section Te, check and uncheck the boxe. With the box checked the valve hould turn on. The valve hould be off with the box not checked. 3. Check the harne connection to that valve. It i a 3-Pin Weather Pack connector. See Section D for wiring diagram 4. Check voltage pin A to Pin B. Mu be 12 volt, if not, go back to 37-pin and check voltage (pin 36 & 37 a +12V, pin 1 & 2 a ground). 5. If voltage i pent on pin A&B of 3 pin connection to valve, then check Pin C to Pin B. Thi hould be 12 volt when the valve i commanded on or open, thi hould be zero volt when Pin Function valve i off or cloed. A B C + 12 V Conant Ground + 12 V Signal Troublehooting Tip 6. If ignal voltage i not pent to open valve, ue diagram to check at the 16 pin, then the 37-pin for voltage on the proper pin for that ection. 7. If conant voltage (Pin A&B) and witched voltage (Pin C&B) a pent, inpect, pair or place the valve. 1. Ueful information i available at Diagnoic Reading Delivery. 2. Check flowmeter operation he. 3. See PWM Duty Cycle (an indication of how fa the pump i running (0-255). Pu Senor i not ading 1. Be u Pu Senor i plugged into Pu Senor 1 connector. Make u the pin whe the harne cw on to the end of the enor have not been bent. 2. Be u Pu Senor i et up and calibrated in the diplay. Setup > > Check the box for Pu Senor 1 > Calibrate Pu Senor > Voltage-baed Calibration > 50 mv/psi. 3. The hould be a gen LED light on the end of the pu enor. Thi may be difficult to ee in daylight. The enor need 12 v. Check between pin B&C on the Pu 1 connector on Y2 harne that connect to the pu enor. If the i no voltage he, check the voltage between pin 11 & 16 on the 16-pin connector labeled PUMP. Troublehooting/Service Guide for PWM Liquid -John Dee 4

5 Other iue 1. My rate won t go low enough. I want 8 gpa, but it won t put down le than 11 gpa. A. Check Setup > Rate > Minimum Flow Rate. Thi can be et at 0.0 or at the low range of your flowmeter. Thi i gal / min not gal / ac. B. Check Setup > > PWM Setup > PWM Setting > Low Limit. Default etting for JD i 15 for electric pump and 60 for hydraulic pump. Thee may be et higher to get the pump to art faer to get to Target Rate ooner, but if et too high, the pump cannot low down enough when your peed drop or when ection cloe. C. On a hydraulic pump, be u the d manual override knob i down and locked on the hydraulic valve. 2. I can t get up to my rate. I want 12 gpa, and I can t get mo than 10 gpa. A. How many GPM a quid to hit your rate? I thi within the pump pecification? On an electric pump, the output of the pump decae a the pu incae. Keep the pu under 40 PSI on an electric y. I a circulation valve open, allowing too much liquid to circulate? B. On a dual electric pump y, check each pump individually to ee that each one i working at capacity. C. I the rainer plugged? If too mall of a meh rainer i being ued, the fluid can gel up around the cen a the fluid i pulled through. D. Doe the pump have enough hydraulic oil to hit the deid rate? If the pump i in erie behind another pump or motor, the hydraulic oil to thi pump may be limited. E. Check Setup > > PWM Setup > PWM Setting > High Limit. Thi hould be 255. F. Go to Diagnoic > Reading > Delivery. What i PWM Duty Cycle while the pump i running (in the field or on a Section Te or Nozzle Flow Check)? 255 mean the pump i being told to run at full peed. G. Run the Section Te and hold the (+) button to peed up the pump. Go to to ee how many GPM a being pumped. Alo, check the pu he. Check the PWM Duty Cycle. H. Run a Nozzle Flow Check. See gal/ac, PSI, gal/min, and PWM Duty Cycle. I. I the flow cal corct? I the width of the implent et corctly? 3. It ptty cloe to the rate, but it won t ever lock in to the rate. Go to Setup > Rate > Rate Smoothing. Check the box for Rate Smoothing. Put 10 in the box. Without Rate Smoothing it i normal for the y to how the rate conantly changing mall amount a you go acro the field. With Rate Smoothing, if the Applied Rate i cloe to the Target Rate, the diplay doe not how all the mall change. 4. When I art up, I get a cen that ay Solution Pump Dry. Thi i not unuual on the Dee diplay. If the flowmeter doe not how flow immediately when you art, thi cen pop up. It i made to protect centrifugal pump that can be harmed quickly if they a dry. Thi i not a probl for diaphragm pump. Thi meage may be opped by going to Setup > > PWM Setup > PWM Setting > Low Limit. Incae the Low Limit o the pump will art faer. 5. What etting do I ue in my diplay for the y? The full cenhot of thee a in Section F of the manual that came with the y. Setup Arrow Tower Electric Liq Fert Tool Set up width, ection, and height witch a needed Section Valve Control Valve 3-Wi PWM Cloe Flowmeter Calibration 3000 gal PWM Setup Alarm Pu Senor Rate Minimum Flow 0.0 or low end of flowmeter (Note: Thi i Gal/ min NOT Gal/ac. Rate Rate Smoothing Check the box 10 Implent He i a ummary of the typical etting: Not everything i hown in thi table. Some y may need to be adjued for better operation. PumpRight Hydraulic gal Troublehooting/Service Guide for PWM Liquid -John Dee 5

6 6. My pu i too high / too low. The pu will be what it i depending on how hard it ha to puh to get the amount of liquid you a moving from the pu enor to whe it leave the y. Thi pu will depend on the product itelf, the volume (gal/min) you a moving and how much riction the i to that flow. The orifice or metering tube will be the primary riction, but it i poible that other part of the y may add to the total pu. The pu a y develop will be le (poibly much le) with water than it will be with a fertilizer product. What pu i too low? You need enough pu to open the check valve. If the pu i too low, ome check valve will open befo other, o that ome row may be flowing while other a not. With 4 lb check valve, we like at lea 8 PSI. With 10 lb check valve, we like PSI. What pu i too high? The a a few product that may have flow characteriic that a better at lower rather than higher pu. With mo product that i not a concern. The plumbing component of a y a rated at 100 PSI or above. On an electric pump y, the pump capacity decae a the pu incae. Our andard Tower pump ha an internal 70 PSI bypa. With an electric pump, we like to ee pu from 10 to 30 PSI. If the pump ha the capacity to hit the rate at higher pu, the i not a probl with doing that, but for long-term operation it would be be to witch to a larger orifice or metering tube. The PumpRight hydraulic pump ha the ability to pump up to 290 PSI. plumb thee with a 100 PSI pu lief valve (PRV) o that plumbing component will not be damaged if high pu develop. Typical operating pu with hydraulic pump will be PSI, but the pump will work fine at PSI if that i needed. If continually running in that high range, conider a larger orifice or metering tube. Lower pu will not necearily duce the velocity of the output am at the row. Converely, higher pu will not necearily incae the velocity of the output am at the row. The velocity of the output am i determined by the volume of the flow and the ize of the opening at the output. Changing the pu by changing an orifice or metering tube upam from the outlet will not affect the velocity of the output am if the flow volume main the ame. Option if pu i too high with orifice: Ue a bigger orifice. Slow down. If pu i too low, ue a maller orifice. With metering tube: Option if pu i too high: Ue a larger diameter tube. Shorten the tube that a on now. Slow down. (The pu in a metering tube i lated to the vicoity of the product. Many product change vicoity a the tperatu change. A product will have a higher vicoity (and thefo higher pu) on a cold morning that it will on a hot afternoon. With metering tube: Option if pu i too low: Switch to a maller diameter tube. Ue a longer tube. See publication Y1 Navigating the Metering Tube Maze for mo information on how metering tube work. See publication Y1 Liquid Component Overview for a decription of all the y component and additional troublehooting/ervice information. See the y manual for your y for mo complete information. Manual and publication a available for download at Alo ee the John Dee manual for the GS3 Diplay and the John Dee Rate Controller for mo information on the etup and operation of thoe component Troublehooting/Service Guide for PWM Liquid -John Dee 6