Proportional Valve Interface - Liquid Version - v.1.2 Operation Principle: Allows a proportional (PWM) valve to be used on older rate controllers that were originally designed for a motorized servo valve. Allows tuning of response speed when this function is not provided by the rate controller. Drives the proportional coil with a varying current by using fixed-frequency pulse-width-modulation. Current is adjusted according to Increase/ Decrease signals from the controller, manual switch, and internally stored settings. Provides fully independent manual speed control in the absence of a controller. Provides Valve-Lock feature (Servo-Lock) Provides separate system response speeds for computer and manual valve control. Inputs: Manual 3-position momentary switch, on-off-on. Returns to off when released. May have more than one swich. (ie- remote reload station pump switch) - Press up, "ON/ Increase" - Press dn, "Decrease/ OFF" Signals from Rate Controller: - Computer Increase - Computer Decrease - Valve Lock input- Prevents computer changes to speed when sprayer boom is OFF. Configuration Switch- part of interface box, pushbutton used for initial setup without need of a laptop PC. - Press to advance setup modes Outputs: - PWM driver circuit. 10 amp Darlington driver circuit w/ flyback diode. - Status Light driver circuit. Controls switch light in Manual Switch. - Full-Power signal output. Signals alarm or other warning when valve is at maximum. (APER signal) EEPROM Variables. These are stored in nonvolatile memory on the MCU chip, and will be retained without power: -Mimimum PWM. The low limit where valve just starts to crack. -Maximum PWM. The high limit when 100% flow is attained. -Starting Point. When the Manual Switch is initially pressed ON, flow will be brought up to this level. -Delta. The speed at which the flow rate is changed when an Inc or Dec signal is present. Separate Delta for manual and computer-controlled speed changes. Operation. Press up on pump switch ("ON/ Increase"). Switch light turns on and pump speed ramps up to the Starting Point level. Press pump switch up or down ("ON/ Increase" or "Decrease/ OFF") to adjust pump speeed manually. Once pump has been manually turned on with the switch, the increase and decrease signals from the rate controller will be received and cause pump speed changes. To turn off the pump, press down and hold the pump switch ("Decrease/ OFF") until pump has stopped and switch light goes out. Once switch light is off, the pump will stay off until manually re-started. Valve-Lock. This feature will prevent the Application Rate Controller from altering pump speed when the operator has turned OFF all sprayer booms. Certain older controllers will attempt to maintain control of the system even with all booms off, and as a result will stop the pump when the vehicle speed is zero. To prevent this behavior, connect the Valve-Lock input wire to the Master Apply signal, and turn on this feature in Config Mode 6. When this feature is active, Switch Light will flash once each time master apply signal turns ON or OFF; to let you know the Valve-Lock signal is working. The manual switch will control the pump regardless of Valve Lock. Full-Scale Signal. -This wire provides a grounded signal when the pump speed is at the MAXIMUM speed allowed. This takes the place of the APER limit switch signal in a mechanical servo valve. Switch Light The Switch Light tells several things. -Off: The system is in standby mode. Pump is OFF. -On Steady: The pump is running (or is ready to respond to computer signals). -Flashing Fast: -The pump is already at full speed and an INCREASE signal is still present. -or- -The pump is already at minimum speed and you are still holding "Dec/ OFF" switch. -Flashing a Code: -Code 1: Config Mode: MAX PWM -Code 2: Config Mode: MIN PWM -Code 3: Config Mode: Starting Point speed -Code 4: Config Mode: Delta Rate for Manual Control -Code 5: Config Mode: Delta Rate for Computer Control -Code 6: Config Mode: Valve-Lock active/ inactive -Code 7: Fault Code: PWM Coil circuit fault -Code 8: Fault Code: Manual Switch circuit fault Using Configuration Mode: You must unlock the configuration mode by turning ON the ignition while holding the Setup Button! Switch light will blink twice to confirm unlock of setup mode. Setup button will then function until ignition is turned off. Press ON/ Inc so pump is running. Switch light should be on. Press and release Setup Button on interface box. This advances to Setup Mode 1. -Mode 1. (MAX) Light will blink single flashes and pump will attain MAXIMUM SPEED. Use Inc/ Dec switch to adjust. This is the maximum PWM duty-cycle you want the system to attain. Press and release Setup Button to save the new MAXIMUM SPEED in memory and advance setup modes. -Mode 2. (MIN) Light will blink two flashes and pump will drop to MINIMUM SPEED. Use Inc/ Dec switch to adjust. This is the minimum PWM duty-cycle you want the system to attain. Set this to where the pump JUST BARELY runs. Press and release Setup Button to save the new MINIMUM SPEED in memory and advance setup modes. -Mode 3. (Starting Point) Light will blink 3 flashes and pump will accellerate to the Starting Point speed. This is the speed the pump will accellerate to when first turned on manually. A good Starting Speed is the minimum pressure for the chemical inductor to function. Adjust with Inc/ Dec switch then press and release Setup Button to save the new value and advance setup modes. -Modes 4 and 5. (Delta Rate) Light will blink 4 or 5 flashes. Mode 4 changes MANUAL delta; mode 5 changes COMPUTER delta. To change the Delta Rate, use the Inc/ Dec switch WHILE HOLDING SETUP BUTTON. The switch light will flash rapidly to indicate the delta rate is changing. Release Setup Button after adjusting Delta Rate. Now, the Inc/ Dec switch will control pump speed. You can now observe the new Delta Rate by changing the speed manually. Press and hold Setup Button while increasing or decreasing Delta Rate as many times as needed. Once satisfied with the new Delta Rate, press and release Setup Button to exit Config Mode 4 or 5. As long as you have pressed increase or decrease while holding the Setup Button, you will not exit this mode when you release the button. -Mode 6. (Valve-Lock) Light will blink 6 flashes. While in this mode, press ON/ Inc to turn ON Valve- Lock; or press Dec/ OFF to turn OFF Valve-Lock. There will be no indication when Valve Lock is turned on or off. Press Setup Button to exit Config Mode. Light should be on steady indicating normal operation after exiting Mode 6. Each time you press the Setup Switch and change modes, any change you made in the previous mode is saved to EEPROM memory. -You can not rapidly advance modes without waiting for the pump speed to reach its set point in each mode. If Delta Rate is very slow this can take several seconds. Service Codes: -Code 7 (Coil Circuit). The MCU didn't see battery voltage on the coil circuit when the driver was "off." This code will only set at lower power levels. Check for open coil, damaged wiring or blown fuse (shorted coil). If pump runs wide open in spite of this code, driver may be shorted or wiring grounded out. -Code 8 (Switch Fault). The MCU received both "ON/ Increase" and "Decrease/ OFF" signals from the manual switch circuit at the same time. Check switch circuit, or one switch stuck on a multi-switch circuit. Water in switches or panel wiring. Full-Scale Signal. -This wire provides a grounded signal when the pump speed is at the MAXIMUM speed allowed. This takes the place of the APER limit switch signal in a mechanical servo valve. Electrical Specifications. Nominal Voltage: +12V DC Input Resistance of signal lines: Deutsch connector pinout: Manual Inc. 200 ohm Pin 1 +12V Pin 11 Valve-Lock input Manual Dec. 200 ohm Pin 2 Ground Pin 12 Full-Scale output Computer Inc. 100K ohm Pin 3 Coil + Computer Dec. 100K ohm Pin 4 Coil - Valve-Lock 200 ohm Pin 5 ON/ Inc. MCU "Sees" voltage at: 6 Volts Pin 6 Dec./OFF Pin 7 Ind. Light Min. Coil Resistance: 2.5 ohms Pin 8 Comp. Inc. PWM Frequency 240 Hz Pin 9 Comp. Dec Coil Driver fuse 5 Amp Pin 10 +12V out Switch Light and Full-Scale Signal drivers protected by 100 ohm internal resistance.