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IntelliFlow
User 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 NOTICE
Hemisphere 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.
TRADEMARKS
Hemisphere 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 CUSTOMERS
Contact 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.
Calgary, Alberta, Canada T2G 3C4
Telephone number: (403) 259-3311
Fax number:
(403) 259-8866
E-mail address:
[email protected]
Warranty Notice
COVERED PRODUCTS
This warranty covers all products manufactured by Hemisphere GPS (the "Products").
HEMISPHERE GPS LLC LIMITED WARRANTY
Hemisphere 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 REMEDY
The 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.
EXCLUSIONS
Hemisphere 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 WARRANTIES
THE 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 LIABILITY
THE 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 LEGISLATION
To 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 SERVICE
In 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 LLC
7560 East Redfield Road Suite B
Scottsdale, AZ 85260
Phone 480.348.9919 Fax 480.348.6370
[email protected]
www.hemispheregps.com
IntelliFlow User Guide
Table of Contents
1: M3 PRE-INSTALLATION . . . . . .1
Unpacking and Inspecting Procedure . . . . . . . . . . . . . . 2
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cable 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 . . . . 9
Cable 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 . . . . . . . . . . . . . . . . . . 30
Power 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 . . . . . . . . . . . . . . . . . . . . . . . . . 77
IntelliFlow, 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
IntelliFlow User Guide
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
IntelliFlow User Guide
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
1: M3 Pre-Installation
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 User Guide
INTELLIFLOW POWER
CONNECTIONS
Figure 1-1 shows the IntelliFlow’s power connections.
Power cable (05-F-3731)
10 Amp breaker
Aircraft power
24 to 36 Vdc
IntelliFlow
controller
Good frame/fuselage grounding point
Figure 1-1. IntelliFlow’s power connection
5
1: M3 Pre-Installation
INTELLIFLOW CABLE
INTERCONNECTION DIAGRAM
Figure 1-2 provides the IntelliFlow cable interconnection.
P1: IntelliFlow
P2: Flow meter
Pressure
switch
P4: Spray off
P3: To M3
Figure 1-2. IntelliFlow cable interconnection
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IntelliFlow User Guide
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.
1.5” x 2” x 2” (09-C-2000)
Hose clamps
(12 each)
Flow meter
Flow
Flow direction
Hose clamps
(26-F-6863)
2” hose
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
7
1: M3 Pre-Installation
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.
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IntelliFlow User Guide
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.
BLACK, 22AWG
Hopper -
RED, 22AWG
Hopper +
BLU/WHT, 22AWG
Flow1 Flow1 +
RED/WHT, 22AWG
BLK/WHT, 22AWG
GRD
ORG/WHT, 22AWG
Flow2 +
WHT, 22AWG
Flow1 +
Shield
BLU/WHT, 22AWG
RX M3
TX M3
BLK/WHT, 22AWG
GRD
Shield
RED/WHT, 22AWG
GRD
BLU/WHT, 22AWG
12+
BLK/WHT, 22AWG
ORG/WHT, 22AWG
RTS
CTS
Shield
Figure 1-4. Connection diagram
9
1: M3 Pre-Installation
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.
12.5 ft
5.5 ft
Switch, 10A, DPDT IntelliFlow
7343K82
Motor/valve
(89-T-1050)
Detail B
Label
(501-560)
Connector, 8P male, Bendix
PTOA-16-8P(SP)
(32-A-3000)
Detail A
Cable, 9C, 16 AWG, shielded
(18-C-0450)
Cable, 9C, 16 AWG, shielded
(18-C-0450)
Connector, 5P, feale, Bendix
MS3116F-14-5S(SR)
(32-A-3280)
or
32-A-3285 Conn
w/ 32-A-3286 shell
Detail C
Figure 1-5. Completed cable
10
IntelliFlow User Guide
Shield
Bypass switch
GRN
ORG
WHT
IntelliFlow
motor valve
BLK
ORG
Note
2PL
WHT/BLK stripe
GRN/BLK stripe
BRN/BLK stripe
BLU
BLK
WHT
RED
N/C
P4 label
Air open and splicing
connections made at SW1
Figure 1-6. Connection diagram
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
IntelliFlow User Guide
INSTALLATION GUIDELINES
INTELLIFLOW UNIT
FOR
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
Aircraft
bypass valve
Aircraft
flow pump
Flow turbine
meter
IntelliFlow
valve
Strainer
Boom
Pressure
sensor
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
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:
Note: The Hemisphere GPS IntelliFlow, Fire/Dry and Spray
OFF controllers are automatically detected by the M3 AirTrac
software.
1.
Open the flow control Setup screen in AirTrac to initialize the
M3 and hardware. “Controller FOUND” will appear below
the
intialization.
in the flow control Setup screen on
18
IntelliFlow User Guide
2.
Click
to search for a connected controller if
the “Controller FOUND” message does not appear.
3.
Click
screen.
in the AirTrac screen to open the Setup 2
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
IntelliFlow User Guide
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
IntelliFlow User Guide
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
IntelliFlow User Guide
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
IntelliFlow User Guide
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
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.
8.
will be active.
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
after
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
IntelliFlow User Guide
GMU INTERCONNECTIONS
ORDER NUMBERS
AND
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.
1
Aux -switches
(05-C-1352)
cable
2
3
4
5
6
7
Figure 4-1. GMU-1/TNG aux switch connections
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
IntelliFlow User Guide
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.
See Figure 4-2 for an example:
RED wire
from GPU
Swath
Adv
button
BLACK wire
ORANGE wire
from GMU
Break
Button
BLACK wire
WHITE wire
from GMU
BLACK wire
GMU aux cable
Pressure switch
Spray on/off
RED wire from
IntelliFlow
BLACK wire from
IntelliFlow cable
Figure 4-2. GMU aux switch connection example
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
IntelliFlow User Guide
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.
Line 2 of the text shows the following:
•
LD: Shows the number of lines sprayed.
•
LS: Shows the number of lines skipped.
•
F#: Shows the field number being sprayed.
Line 3 of the text shows the following:
•
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.
Line 4 of the text shows the following:
•
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.
Note: Keep a personal record of the turbine CAL factor
according to turbine serial number.
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).
36
IntelliFlow User Guide
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?
Note: This could be normal if using a microswitch on the
spray handle.
•
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
Valve position number
Press the Run Screen key to exit this screen.
38
IntelliFlow User Guide
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
Note: The above valve position values can change
according to valve typ and size.
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)
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
IntelliFlow User Guide
5.
Check pressure switch.
•
Remove the Aux switch I/O connector plug, where the
pressure switch connects, from the IntelliFlow controller.
Note: If the pressure switch is stuck in the closed position,
then the valve will not move.
•
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.
43
Appendix A: M3/IntelliFlow Troubleshooting
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:
7.
8.
•
1050 = Valve fully open +/- 50
•
1550 = 3/4 open +/- 50
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.
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 pickup point of the sensor. This can also be used as a general
reference to the working condition of the IntelliFlow control
44
IntelliFlow User Guide
unit and M3. 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 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.
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:
45
Appendix A: M3/IntelliFlow Troubleshooting
•
Check all wiring connections and terminal strips.
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.
•
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.
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.
•
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.
46
IntelliFlow User Guide
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
Appendix A: M3/IntelliFlow Troubleshooting
IntelliFlow Bench System Troubleshooting
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.
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.
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.
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.
48
IntelliFlow User Guide
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: Microprocessor startup is a low beep.
•
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.
49
Appendix A: M3/IntelliFlow Troubleshooting
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.
If the previous operation is normal:
1.
Maintain power to the IntelliFlow control unit.
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.
Note: The flow status/valve position must be selected to
observe it on the viewscreen.
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.
7.
Toggle the normal/bypass switch to the normal position.
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.
50
IntelliFlow User Guide
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
Appendix A: M3/IntelliFlow Troubleshooting
•
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
IntelliFlow User Guide
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
Appendix A: M3/IntelliFlow Troubleshooting
•
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
IntelliFlow User Guide
5.
Check pressure switch.
•
Remove the Aux switch I/O connector plug, where the
pressure switch connects, from the IntelliFlow controller.
Note: If the pressure switch is stuck in the closed position,
then the valve will not move.
•
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.
57
Appendix B: Flying Flagman Troubleshooting
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 touch screen flow status run screen by entering
the following into the Flying Flagman:
DISPLAY, 7
Status
Valve position number
Valve Position:
•
1050 = Valve fully open +/- 50
•
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.
58
IntelliFlow User Guide
8.
Observe the touchscreen flow status Run Screen vavle position
number.
Valve Position:
9.
•
1050 = Valve fully open +/- 50
•
1550 = 3/4 open +/- 50
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 pickup 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
Appendix B: Flying Flagman Troubleshooting
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.
11. 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)
12. In addition to the following procedures, check the following:
•
Check all wiring connections and terminal strips.
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.
•
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.
60
IntelliFlow User Guide
•
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.
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.
•
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
61
Appendix B: Flying Flagman Troubleshooting
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 User Guide
IntelliFlow Bench System Troubleshooting
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.
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.
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.
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.
63
Appendix B: Flying Flagman Troubleshooting
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: Microprocessor startup is a low beep.
•
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.
64
IntelliFlow User Guide
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.
If the previous operation is normal:
1.
Maintain power to the IntelliFlow control unit.
2.
Toggle the sensor switch to the open position.
3.
Observe the CDU flow status Run Screen by entering the
following:
DISPLAY, 7
Status
Valve position number
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.
7.
•
1050 = Valve fully open +/- 50
•
1550 = Valve 3/4 open +/-50
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.
65
Appendix B: Flying Flagman Troubleshooting
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
IntelliFlow User Guide
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
Appendix B: Flying Flagman Troubleshooting
•
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
IntelliFlow User Guide
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
Appendix B: Flying Flagman Troubleshooting
•
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
IntelliFlow User Guide
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.
4.
Check the following if the unit is blowing fuses:
•
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
Appendix C: Spay Off Unit
•
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
IntelliFlow User Guide
Figure C-1 Shows the spray off automated control interface cable
interconnections.
Wires: white, black and green
are 180” long
Fuse holder
180”
Cable part (05-F-2147)
Aircraft BUSS 24 Volts
Connect to GMU data port P3
Cable color
WHITE
Brake control interface box
(09-F-4000)
10 Amp C/B
Cable color BLACK
Aircraft ground
Cable color GREEN
Clutch/brake cable
(05-F-2148)
C/B load side
Connect to M3 aux IntelliFlow
P4 plug
Solenoid load side
Brake Solenoid
Diode 100 PIV 3 Amps
(41-C-2600)
Brake stick switch
Aircraft ground
Figure C-1. Spray off automated control interface cable
interconnections
75
Appendix C: Spay Off Unit
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
IntelliFlow User Guide
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)
Connector, 10-6P male
MS 3111F-10-6P
(32-A-1375)
Detail C
P2 label
Connector, 10-6P male
MS3111F-10-6P
(32-A-1375)
detail C
Cable, 2C, 22AWG, shielded
(18-C-0460)
156”
48”
24”
2”
2
2
Labels
1
2 ft.
2”
Label
Connector
10P-M, Bendix
PT06A-12-10P(SR)
(32-A-3100)
detail A
1”
Cable, 6C, 22AWG,
Shielded
(850-304)
P4 label
Connector 10-6P male
MS 3111F-10-6P
(32-A-1375)
Detail C
Connector, 8P male
MS3111F-10-6P
(32-A-1375)
detail C
2
Cable, 6C, 22AWG, shielded
(850-304)
Figure C-2. Spray-off cable
77
Appendix C: Spay Off Unit
Cable Assy, External, Spray OFF, M3 Cable (Part number
05-F-2015)
8 Pin male conn.,
mates to VRC/COM1/M3
Connector, 8P
male,282-8PG-321
(32-B-3554)
15”
Heatshrink, ref
Label Note 1
156”
Connector, 6P female,
PW6F 10-6S
(32-A-2885)
Figure C-3. Spray-off only cable
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
Description
Quantity
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
IntelliFlow User Guide
Table D-3: IntelliFlow hoses
Part
number
Description
Quantity
26-F-6828
Hose clamp stainless steel max
2.25 in
8 or 12 pieces
26-F-6836
Hose clamp stainless steel max
2.75 in
8 or 12 pieces
26-F-6844
Hose clamp stainless steel max
3.25 in
8 or 12 pieces
26-F-6852
Hose clamp stainless steel max
3.75 in
8 or 12 pieces
Table D-4: Hose turbines
Part
number
Description
Quantity
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 15180 GPM
One
29-C-0310
Flow turbine S.S. 2 in x 2 in x 2 in 30380 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
Description
Quantity
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 15180 GPM
One
29-C-0310
Flow turbine S.S. 2 in x 2 in x 2 in 30380 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
Description
Quantity
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
IntelliFlow User Guide
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
Description
Quantity
875-0166
Warranty page
One
875-0180
IntelliFlow user guide
One
83
www.hemispheregps.com
e-mail: [email protected]