Solution System

N89470-UN-24SEP10

1 - Load Station Control Panel

2 - Quik-Fill™ Valve

3 - Centrifugal Pump

4 - Solution Tank

5 - Rinse Tank

6 - Pressure Strainer

7 - Eductor Hopper

8 - Orifice Valve

9 - Boom Section Shut-off Valves

10 - Spray Nozzles

11 - Shut-Off/Solution Tank Outlet Valve

12 - Bypass Fill Inlet

13 - Agitation Nozzles

14 - Hydraulic Motor

15 - Bleed-off Line

16 - Rinse Tank Fill Valve

17 - Fresh Water Inlet Valve

18 - Agitation / Rinse System Valve

19 - Bypass / Eductor Valve

20 - Agitation Flow Rate Valve

21 - Tank Rinse Nozzles

22 - Fill Strainer

23 - Solution Flowmeter(s)

24 - Eductor Venturi

25 - Eductor Rinse Valve

26 - Eductor Hopper Valve

27 - Check Valve

28 - Boom Pressure Strainers (Optional)

29 - High Flow Shut-off Valve

30 - Spray Rate Controller (SRC)

31 - Proportional Valve

32 - Wheel Speed Sensor (Left-hand Rear Wheel)

33 - Radar

34 - Pressure Transducer

35 - GreenStar Display

36 - Boom Supply Bleed Line

37 - Flowmeter Shut-off Valve

System Components

The Solution Command System consists of load station control panel (1), Quik-Fill valve (2), centrifugal pump (3), solution tank (4), rinse tank (5), three electric flow control valves (17,18,19), pressure strainer (6), eductor hopper (7), orifice valve (8), boom section shut-off valves (9), and spray nozzles (10) mounted on the boom.

Solution tank is made from stainless steel and has a capacity of 4542 L (1200 gal). A tank lid opening is located at the top of the tank. At the side of the tank is a sight tube and graduated scale that indicates solution level in liters and gallons. Located at the bottom of the solution tank is an air actuated shut-off/solution tank outlet valve (11), a bypass fill inlet (12), and agitation nozzles (13).

The load station control panel allows operator to direct the pre-programmed solution system functions.

The Quik-Fill valve allows the operator to control flow of solution into system when reloading.

The solution pump is a centrifugal type that is driven by hydraulic motor (14). Engagement and disengagement of the pump is controlled by a switch located on the side console. It can also be activated by the pre-programmed functions of switches on the load station control panel. Any air trapped in the pump is allowed to escape through a bleed-off line (15). This helps prevent pump cavitation and allows pump priming. A bleed off line (36) is also provided on the boom supply line to help remove air from the system.

The rinse tank can be loaded, through rinse tank fill valve (16), with clean water for rinsing solution system.

The three electric flow control valves are used to direct flow of solution in system. They are:

• Fresh Water Inlet Valve (17)
• Agitation / Rinse System Valve (18)
• Bypass / Eductor Valve (19)

The Fresh Water Inlet valve allows water to flow to solution pump for:

• Solution system rinse.

The Agitation / Rinse System valve is a three way valve that has following functions:

• Directs solution from solution pump through agitation flow rate valve (20) to four agitation nozzles.
• Directs solution from solution pump to tank rinse nozzles (21) and fill strainer (22) (optional) for solution system rinse.

Agitation jets are in four locations on the bottom of the tank. The jet creates a vigorous fan type agitation throughout the tank to keep chemicals, such as wettable powders, in suspension. The agitation flow rate valve is located under back side of solution tank and can be adjusted to attain the desired agitation effect. The agitation is controlled by a switch on the CommandARM™ in cab that can be used to turn the agitation on and off. It can also be activated by the pre-programmed functions of switches on the load station control panel.

The pressure strainer is located in the boom feed line before the solution flowmeter(s) (23). The filter removes sediment before it reaches flowmeter and boom valves.

Bypass / Eductor Valve is a three way valve that:

• Directs solution from solution pump to solution tank for bypass filling.
• Directs solution to eductor venturi (24).
• Directs solution to eductor rinse valve (25).

The bypass / eductor valve directs solution through a eductor venturi at top of the solution tank to create a vacuum to pull the chemical into the solution tank from the bottom of the eductor. The eductor hopper valve (26) allows chemical to be drawn from bottom of eductor hopper to top of solution tank. The eductor rinse valve directs water to the hopper rinse and the jug rinse.

Check valves (27) are used in the system to prevent solution from flowing in wrong direction.

The flowmeter shut-off valve (37) and can be closed to aid in cleaning the boom pressure strainer(s) (28) and the flowmeter(s) (23).

An orifice valve is located on the boom to the left of the flowmeter(s). It can be used to improve the control of the spray rate control system when smaller nozzles are used.

Boom section shut-off valves are motorized ball valves that cycle completely open or completely closed. The valves are operated by switches on the operator's side console.

The spray nozzles, located on the center frame and boom, meter, atomize and dispense the solution into specific patterns. Solution flow is metered by the size of the orifice in the nozzle tip. Within limits, solution flow through a nozzle can be increased or decreased by adjusting system pressure.

Most nozzles are designed for optimum performance at specific pressures. However, the range of adjustment is relatively narrow. Line pressures too high or too low will affect atomizing the solution and create variations in the spray pattern. The solution atomizes when the liquid is forced through the orifice in the nozzle. The shape of the spray pattern is determined by the shape of the orifice.

System Operation

When the pump is activated, solution is drawn from the solution tank through the shut-off/solution tank outlet valve. The pump pushes the solution to the pressure strainer and on to the spray control valves.

When the spray control valves are open, the solution flows through the boom pressure strainers (28) (if equipped) to the nozzles, where it is atomized and sprayed.

As a general guideline, one flowmeter should be used for less than 341 Lpm (90 gpm). Above 341 Lpm (90 gpm) may require the use of two flowmeters included in the high flow pump option. To use two flowmeters shut off valve (29) should be opened and SprayStar should be programmed for high solution flow.

The flowmeters on the boom send an electronic signal to the spray rate controller (SRC) (30), which compares that signal to the operator-programmed application rate. If there is a difference in the signal from the flowmeters and the programmed rate, the proportional valve assembly (31) will open or close as needed until the system is stabilized.

When the proportional valve opens, more hydraulic oil is sent to the hydraulic motor, causing the solution pump to increase its flow. When the proportional valve closes, less hydraulic oil is sent to the hydraulic motor, causing the solution pump to decrease its flow.

The Spray Rate Controller (SRC) provides the ability to maintain application within a range of application rates while changing speeds. Application rate consistency depends on a number of things such as nozzle tip size, application rate, and rate of speed change. The SRC provides quick response, but some differences in application rates can be observed if the operator makes rapid speed changes or operates at the extremes of the solution pressure range.

Principle parts of the SRC system are a speed sensor (either a wheel speed sensor (32) on left rear wheel motor or a radar speed sensor (33) at front of machine), the spray rate controller, a variable speed solution pump, a flowmeter, and a solution pressure transducer (34). The speed sensor and flowmeter provide speed and flow rate information to the spray rate controller. The spray rate controller provides target (programmed by the operator) application rates by analyzing speed and flow data, and then making appropriate adjustments to the variable solution pump.

The spray rate controller (SRC) is mounted on the boom support structure on right-hand side of machine. The spray rate controller has an internal warning system that alerts the operator if the actual flow rate varies from the programmed flow rate by 20% of actual for more than 10 seconds. The SRC system is a volume-regulating system, so pressures displayed on the GreenStar display (35) may vary at a given ground speed.

The solution pressure required for a given application rate is determined by speed and nozzle tip size. Before attempting to use the SRC, refer to a nozzle tip calculator or nozzle tip selection charts, and make sure the spray boom is equipped with spray tip nozzles that will provide desired application rates at desired pressures and speeds. Ground speed variation is limited by the operating pressure range of the nozzle tips.

The Master “on/off” switch located on the multifunction control handle is an integral part of the SRC system. When “off” is pushed, electrical power closes the boom section valves and the variable solution pump slows to maintain spray-off pressure (as set by the operator).

Solution may continue to spray from the boom for a short period of time after master “off” is pushed. This is due to pressure remaining in the line. The time interval that spray will continue flowing depends upon pressure in the spray line, boom hose lengths and routings, nozzle tip size, and use of nozzle check valves. In order to compensate for the boom shut-off lag time, master “off” should be pressed prior to reaching the turnrow.

Once Master “on” has been pressed, if the machine is moving slowly or is not moving, the variable solution pump will maintain the minimum solution pressure as set by the operator. This may result in an application rate that is higher than the target rate (programmed by the operator). Likewise, if the machine is moving too fast, the variable solution pump will maintain the maximum solution pressure. This may result in an application rate that is lower than the target rate.