Netafim Fertikit 3G User manual

FERTIKIT 3G SPLIT (SP) NPT
USER MANUAL

2 FERTIKIT USER MANUAL
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.TO ITS PRODUCTS AND/OR ASSOCIATED DOCUMENTATION WITHOUT PRIOR NOTICE

FERTIKIT USER MANUAL 3
TABLE OF CONTENTS
Symbols ......................................................................................... 5
Introduction
Safety Instructions ................................................................... 6
When Using Acid/Chemicals .................................................. 7
Description
Introduction ............................................................................... 8
Advantages ................................................................................ 8
Specifications ............................................................................ 8
Basic Functions ........................................................................ 9
Operating Principle .................................................................. 9
Service ....................................................................................... 9
Add-ons ...................................................................................... 9
SP ................................................................................................ 10
Typical Setup.............................................................................. 11
Dimensions ................................................................................ 13
Weights ...................................................................................... 13
Operation & Maintenance
Maintenance ............................................................................. 14
Winterization ............................................................................. 15
Troubleshooting
Symptoms for More Than One Single Dosing Channel ...... 16
Symptoms for a Single Dosing Channel ............................... 17
Symptoms While Idle ............................................................... 19
Switchboard Warning ............................................................. 19
Calibration
Calculation of Dosing Channels Opening Percentage ....... 20
Simulation with 2 Gallon Bucket of Water ........................... 20
Calibration of FertiKit While Irrigating ................................. 22
Warranty ....................................................................................... 24
FertiKit Parts
SP................................................................................................. 25

4 FERTIKIT USER MANUAL

FERTIKIT USER MANUAL 5
EXAMPLE
The following text provides an example to clarify the operation of the settings, method of operation or
installation.
The values used in the examples are hypothetical. Do not apply these values to your own situation.
WARNING
The following text contains instructions aimed at preventing bodily injury or direct damage to the crops,
the FERTIKIT and/or the infrastructure.
CAUTION
The following text contains instructions aimed at preventing unwanted system operation, installation or
conditions that, if not followed, might void the warranty.
ATTENTION
The following text contains instructions aimed at enhancing the efficiency of usage of the instructions in
the manual.
NOTE
The following text contains instructions aimed at emphasizing certain aspect of the operation of the
system or installation.
SAFETY FOOTWEAR
The following text contains instructions aimed at preventing foot injury.
TIP
The following text provides clarification, tips or useful information.
ACID HAZARD
The following text contains instructions aimed at preventing bodily injury or direct damage to the crops,
the FERTIKIT and/or the infrastructure in the presence of acid.
ELECTRICAL HAZARD
The following text contains instructions aimed at preventing bodily injury or direct damage to the
FERTIKIT and/or the infrastructure in the presence of electricity.
The symbols used in this manual refer to the following:
PROTECTIVE EQUIPMENT
The following text contains instructions aimed at preventing damage to health or bodily injury in
the presence of fertilizers, acid or other chemicals.
SYMBOLS

6 FERTIKIT USER MANUAL
WARNING
Measures must be taken to prevent fertilizer infiltration of the water source.
WARNING
When handling fertilizers, acid and other chemicals, always use protective equipment, gloves and
goggles.
WARNING
In agricultural environment - always wear protective footwear.
CAUTION
When opening or closing any manual valve, always do it gradually, to prevent damage to the system by
water hammer.
Safety Instructions
•All safety regulations must be applied.
•Ensure that the installation is carried out in a manner that prevents leaks from the FERTIKIT,
the fertilizer/acid tanks and lines, the peripherals and the accessories, contaminating the
environment, soil or ambient area.
•Electrical installation must be performed by an authorized electrician only.
•The electrical installation must comply with the local safety standards and regulations.
•Protection provided by the equipment can be impaired if the equipment is used in a manner other than
that specified by the manufacturer.
NOTE
The maximum sound level produced by the equipment does not exceed 70dB.
INTRODUCTION

FERTIKIT USER MANUAL 7
ACID HAZARD
When using acid/chemicals - always observe the manufacturer's safety instructions.
When Using Acid/Chemicals
WARNING
When handling fertilizers, acid or other chemicals, always use protective equipment,
gloves and goggles.
WARNING
Exceeding the above acid concentrations will damage the dosing channels.
WARNING
Substances such as chemicals for pest/disease control might be corrosive and damage the FERTIKIT. When
using any substance other than fertilizers or acids not exceeding the concentrations in the table above,
always observe the manufacturer's instructions for corrosivity.
In case of any doubt, consult your Netafim representative.
ATTENTION
When dosing acid, use a dosing channel fitted with the appropriate components
according to the type and concentration of the acid used*:
For pH correction For maintenance of drippers
Type of dosing channel
Diaphragm
and O-rings
Nitric
(HNO3)
Phosphoric
(H3PO4)
Sulfuric
(H2SO4)
Hydrochloric
(HCl)
Hydrogen
peroxide
(H2O2)
Chlorine (as
hypochloride)
For diluted acid EPDM <3% <85% <30% <10% <30% <1%
For concentrated acid Viton <40% <85% <90% <33% <50% <10%
% is by weight at 70oF
* The table indicates the resistance of the dosing channel components to acid,
and is not a recommendation to use the acids mentioned.
INTRODUCTION

8 FERTIKIT USER MANUAL
Introduction
The FERTIKIT 3G is a fully configurable, highly cost-effective solution for precise NutrigationTM.
The FERTIKIT 3G maximizes the usage of available water flow rates and pressures on the main irrigation line
ensuring the highest efficiency with minimum investment. The FERTIKIT 3G can operate under various modes and
accommodate a variety of dosing channels, dosing boosters, controllers, peripherals and accessories to meet a vast
range of applications and infrastructure constraints.
Advantages
•A modular NutrigationTM system for soil or substrate applications with minimum investment
•Efficient usage of water, fertilizers and energy
•Unrivaled range of irrigation water capacities
•Designed for any application where quantitative or proportional NutrigationTM is required
•Highly profitable price/performance ratio
•Venturi operating principle - no moving parts
•Fits easily into any existing irrigation system
•Precise NutrigationTM based on high-accuracy dosing channels
•Quick action dosing valves
•Available with up to 4 fertilizer/acid dosing channels
•NutrigationTM recipes can be changed quickly and efficiently
•Can be operated manually or fully computerized
•NMC and other controllers can be assembled on the FERTIKIT for advanced NutrigationTM control
• A wide variety of accessories and peripherals can be integrated into the FERTIKIT to enhance its functions
•High-quality components and PVC pipe work
•Aluminum, corrosion-resistant frame with adjustable legs
•Easy to install and to maintain
•Made by Netafim
Specifications
Capacity Range
The FERTIKIT ensures a satisfactory mixture in an extremely vast range of flow capacities.
It will accommodate a large range of applications.
Fertilizer Dosing Capacity
The FERTIKIT 3G SP's basic platform accommodates up to 4 dosing channels of various types:
•13 GPH •35 GPH •95 GPH
* For applications requiring more than 4 dosing channels - consult Netafim.
Mainline Pressure Range
Typical main line pressure ranges and conditions, by mode:
SP - For applications where the main line pressure is between 15 and 60 psi and sufficient
for irrigation with no excess.
DESCRIPTION

FERTIKIT USER MANUAL 9
Basic Functions
The FERTIKIT supports the following NutrigationTM functions:
• Fully controlled dosing and mixing of fertilizers/acid with source water into a homogenous nutrient solution.
•EC/pH correction of the nutrient solution.
•Water pre-treatment
Operating Principle
The FERTIKIT doses the various fertilizers and acid into a homogeneous solution and injects it into the irrigation
water main line. The suction of the fertilizers and acid in the dosing channels is based on the Venturi principle. The
FERTIKIT booster pump creates the pressure differential to drive the dosing channels.
Service
Servicing the FERTIKIT 3G is a prompt and simple process. The dealer keeps a small quantity of interchangeable
components on hand, for replacement on site within a few minutes.
Add-ons
The FERTIKIT functionality can be extended by means of the many add-ons offering a wide variety of useful
functions. All the add-ons are easy to connect to the FERTIKIT - here are a few examples:
Fertilizer Meter
Enables continuous reading of fertilizer dosing. Useful in applications where EC/pH control is not performed.
Stock Selection
Enables the dosing of multiple fertilizers through a single dosing channel (in cases they where simultaneous dosing
is not required).
Available in a wide variety of configurations, from a single dosing channel with 2 fertilizers to as many dosing
channels and fertilizers as required.
For further information on the FERTIKIT add-ons, consult Netafim.
DESCRIPTION

10 FERTIKIT USER MANUAL
SP
For applications where the main line pressure is between
15 and 60 psi and is sufficient for irrigation with no excess.
The pressure differential required to generate fertilizer suction
via the Venturis is produced by a boost pump integrated in the Fertikit.
This mode of operation, where the system pump is installed upstream from
the Venturis, permits the use of a smaller pump, reducing the investment
required and saving energy.
Total fertilizer/acid suction capacity - up to 380 GPH.
Accommodates a wide variety of dosing channels for fertilizer and
concentrated/diluted acid: Up to 4 dosing channels, from 13 GPH each, up to
40 GPH each. Available in 13 GPH, 35 GPH, and 95 GPH each.
Schematic Diagram




DESCRIPTION

FERTIKIT USER MANUAL 11
DESCRIPTION
Typical Setup
pressure reducing valve (PRV)
pressure sustaining valve (PSNO)

12 FERTIKIT USER MANUAL
DESCRIPTION
Typical Setup
Required Proportions
For optimal operation of the FERTIKIT, piping must be installed while maintaining the following proportions.

FERTIKIT USER MANUAL 13
Dimensions
With Controller Without Controller
H
D
W
H
D
W
Configuration
FERTIKIT external dimensions (W/D/H*) Package dimensions (W/D/H**)
Without controller 33/40.5/36" 39.5/45.5/39.5"
With controller 33/40.5/53" 39.5/45.5/63.5"
Weights
With dosing booster
Mode Controller
4HM9 CM5 CM15
Net weight Packed
weight Net weight Packed weight Net weight Packed weight
SP
Without 110 lbs. 165 lbs. 139 lbs. 194 lbs. 198 lbs. 254 lbs.
With 132 lbs. 194 lbs. 161 lbs. 223 lbs. 220 lbs. 282 lbs.
**The package height includes the
pallet height of 4".
*The height varies by ±0.5"
according to the adjustment of the legs.
DESCRIPTION

14 FERTIKIT USER MANUAL
Maintenance
CAUTION
When opening or closing any manual valve, always do it gradually, to prevent damage to the system by
water hammer.
To prevent failures and extend the life cycle of the FERTIKIT, the user must carry out regular maintenance.
•Keep the FERTIKIT dosing unit and its immediate environment clean and dry.
CAUTION
Before calibrating the EC and pH sensors, gradually close the isolation valves and open the
sampling valve until the pressure in the system is released.
•The FERTIKIT dosing unit and the supply water and irrigation system must be inspected regularly.
Regular Inspection
Description How often Instructions
Rinsing of fertilizer filters* Once a day
Rinsing of supply water filters* Once a day
Water and fertilizer leak inspection Once a week Visual inspection
Calibration of the pH sensor Every 2-4 weeks See the EC/pH Transducer Manual
Calibration of the EC sensor Every 4 weeks
* Manual filters only.
Check the FERTIKIT Hydraulic Conditions Every 4 Weeks
Consult the main line flow meter and pressure gauge, the upper manifold and lower manifold pressure gauges and the
visual flow meters of the dosing channels, fill in the data on the FERTIKIT Hydraulic Conditions Checklist provided by
the installer and make sure that all the hydraulic conditions match the reference data.
When verifying the flow rate for each dosing channel, make sure the cursors on all the visual
flow meters are adjusted.
NOTE
The visual flow meter's scale is calibrated by the manufacturer for measurement
of the flow rate of water (H2O). Certain inacuracies may be observed when the flow
rate of liquids with different densities, such as fertilizers and acids, is measured.
ATTENTION
Once a month, read the measured flow rates of the dosing channels
and compare them with the flow rates defined in the controller,
to check whether any changes have occurred.
OPERATION & MAINTENANCE

FERTIKIT USER MANUAL 15
Winterization
CAUTION
When opening or closing any manual valve, always do it gradually, to prevent damage to the system by
water hammer.
In areas susceptible to freezing temperatures, if the system is not required for irrigation during the winter (mainly in
open field applications) perform the following procedure to avoid damage caused by freezing when the FERTIKIT is idle
for the winter period:
At the beginning of winter:
•Gradually close the isolation valves and open the sampling valve until the pressure in the system is released.
• Remove EC and pH sensors and store the pH sensor immersed in KCL solution (supplied with the sensor)
or in calibration buffer 4 at temperature 64 - 77˚F. The pH sensor must never be dry (see EC/pH Transducer Manual).
•Empty the FERTIKIT of water.
At the end of winter:
•Reinstall the EC and pH sensors and calibrate them (see EC/pH Transducer Manual).
•Gradually open the isolation valves until the pressure in the system is restored.
OPERATION & MAINTENANCE

16 FERTIKIT USER MANUAL
This section is a systematic guide to the actions to be taken in the case of a malfunction of the FERTIKIT.
ATTENTION
Before proceeding to troubleshoot any malfunction, make sure that:
•The controller settings regarding the dosing channels are correct and match the dosing channels
of the FERTIKIT (see the Controller Manual).
•The controller settings regarding the field valves are correct (see the Controller Manual).
Perform the actions in their order of appearance until the malfunction is fixed.
If you identify faulty parts - consult your Netafim representative.
CAUTION
Only qualified electricians are permitted to perform electrical installations and repairs!
CAUTION
If isolation valves have been installed on the system, ensure that they are in closed position before
troubleshooting any hydraulic malfunction.
ATTENTION
If fertilizers from a different manufacturer have been recently in use and changes in EC and pH are
recorded, perform calibration of the system before assuming a malfunction of the FERTIKIT
(see Calibration on page 19).
Symptoms For More Than One Single Dosing Channel
If one or more of the following symptoms occur regarding more than one single dosing channel,
perform the actions listed bellow:
Controller Warnings
•Low EC
•High pH
•Low fertilizer/acid flow rate
Visual Flow Meter Reading
•Low fertilizer/acid flow rate
Action
1) For controller warnings only - check and calibrate the EC and pH sensors (see the EC/pH Transducer Manual).
2) Have a qualified electrician check that electricity is being supplied to the FERTIKIT and that all the electrical
components are properly connected (see the Switchboard Manual).
3) Check that the hydraulic conditions comply with the reference data in the FERTIKIT Hydraulic Conditions
Checklist.
If NO, restore the original hydraulic conditions according to the reference data in the FERTIKIT Hydraulic
Conditions Checklist.
If YES or if the malfunction is still not fixed after restoring the original hydraulic conditions, in SP model -
have a qualified electrician check the dosing booster:
Does it function? Does it rotate in the correct direction?
If not - the electrician should swap between phases L1 and L3 (see the Dosing Booster Manual). This only applies
to Phase 3 booster pumps.
TROUBLESHOOTING

FERTIKIT USER MANUAL 17
4) Check for an air pocket in the dosing booster impeller chamber (see the Dosing Booster Manual):
Open the FERTIKIT sampling valve until a stable flow, free of air-bubbles, is obtained.
5) If the original hydraulic conditions are still not restored - loosen the dosing booster's bleeding screw
and wait until a stable flow, free of air-bubbles, is obtained, then retighten the bleeding screw
(see the Dosing Booster Manual).
6) Check the dosing booster's impeller chamber for clogging:
If it is clogged - it should be dismantled and thoroughly cleaned (see the Dosing Booster Manual).
If after implementing all the above steps the malfunction is still not fixed - consult your local Netafim Dealer.
Symptoms For a Single Dosing Channel
If one or more of the following symptoms occur regarding a single dosing channel, perform the actions listed below:
Controller Warnings
•Low EC
•High pH
•Low fertilizer/acid flow rate
Visual Flow Meter Reading
•Low fertilizer/acid flow rate
Action
1) Check that there is fertilizer/acid solution in the stock tank A.
2) Check that the stock tank manual valve Bis in the OPEN position.
3) Check that the fertilizer/acid filter Cis clean - If not, it should be dismantled and thoroughly cleaned.
4) Check the fertilizer/acid line D(from the stock tank to the dosing channel) for leaks and breaches
and make sure all the connectors are tightened.
5) Make sure the dosing channel's needle valve Eis open according to the reference data in the
FERTIKIT Hydraulic Conditions Checklist.
6) Visually check the needle valve Efor chemical damage (internal deformation). If internal deformation is present,
replace the needle valve.
7) Visually check the needle valve Efor clogging. If clogging is present - thoroughly clean the needle valve.
8) Check that the dosing valve Fis functioning:
With the controller in MANUAL mode, set the dosing valve Fto ON (see the Controller Manual).
The LED on the dosing valve should be lit.
- If it is not - have a qualified electrician check the dosing valve's cable for electrical continuity.
- If the cable is in working order - check the controller (see the Controller Manual).
- If the controller and the cable are in working order - toggle the dosing valve
Fto OFF and again to ON
in the controller (see the Controller Manual). A 'Click' should be heard from the dosing valve with
each toggle - If a 'Click' is not heard, replace the dosing valve (consult your Netafim Dealer).
- If a 'Click' is heard and the dosing valve Fstill does not open - disconnect the dosing valve from the dosing
channel and with the dosing valve set to ON in the controller (see the Controller Manual), check for clogging
by injecting water at low pressure through the dosing valve.
TROUBLESHOOTING

18 FERTIKIT USER MANUAL
A
B
C
D
E
F
G
H
- If there is clogging - thoroughly clean the dosing valve Fwith running water.
- If there is no clogging and the dosing valve Fstill does not open - replace it (consult your Netafim Dealer).
9) Visually check the non-return valve Gfor any internal deformation or damage to its flat ring gasket.
If present - replace the non-return valve (consult your Netafim Dealer).
10) Check the non-return valve Gfor clogging by injecting water at low pressure through it (make sure to respect
the direction of flow). If there is clogging - thoroughly clean the non-return valve Gwith running water.
11) Disconnect the Venturi Hfrom the manifolds and from the dosing channel and check it for clogging,
visually and by injecting water at low pressure through it. If there is clogging - thoroughly clean the Venturi H
with running water.
12) Visually check the Venturi Hfor chemical damage (internal deformation). If internal deformation is present -
replace the Venturi (consult your Netafim Dealer).
If after implementing all the above steps the malfunction is still not fixed - consult your Netafim Dealer.
TROUBLESHOOTING

FERTIKIT USER MANUAL 19
Symptoms While Idle
If the following symptoms occur while the FERTIKIT is idle, perform the actions listed below:
Controller Warnings
•High EC
•Low pH
•While idle - uncontrolled fertilizer/acid flow rate or a fertilizer/acid leak or breach
Action
NOTE
The fertilizer dosing channels have a dosing valve (model: Fip S12), make sure the dosing valve
selector is in the CLOSED position.
Check if the dosing valves leak when closed:
1) Close all the manual valves Bfor fertilizers and acid.
2) Make sure the level of the solution in all the the stock tanks is higher than the
dosing valves.
3) With the controller in MANUAL mode, set all the dosing valves to OFF
(see the Controller Manual).
4) Disconect one of the the dosing valves from the non-return valve (downstream
from the dosing valve).
5) Open the fertilizer manual valve B.
If a leak from the dosing valve is visible - disconect the dosing valve from the
dosing channel.
6) With the controller in MANUAL mode, set the dosing valve to ON (see the
Controller Manual).
7) Thoroughly clean the dosing valve with running water.
8) Repeat steps 4-7 for each fertilizer and acid dosing channel.
9) After completing the procedure, open all the manual valves Bfor fertilizers and acid.
10) If the malfunction is still not fixed - replace the dosing valve .
If after implementing all the above steps the malfunction is still not fixed - consult your Netafim Dealer.
OPEN CLOSE
Switchboard Warning
If the following symptom occurs during operation, perform the actions listed below:
Switchboard Warning Light
•The switchboard warning light is on (when the dosing booster is either ON or OFF).
Action
1) Check if the pressure on the main line is low compared with the reference data on the FERTIKIT Hydraulic
Conditions Checklist: If YES, restore the original main line pressure.
2) Check if the overload protection breaker is ON (see the Switchboard Manual). Toggle it OFF and ON again.
If the switchboard warning light is still on or the overload protection breaker trips (turns to OFF) again,
have a qualified electrician check if the dosing booster is in working order (see the Dosing Booster
Manual) and check if there are irregularities in the electricity voltage supplied to the FERTIKIT.
If after implementing all the above steps the malfunction is still not fixed - consult your Netafim Dealer.
TROUBLESHOOTING

20 FERTIKIT USER MANUAL
The process of calibrating the FERTIKIT is carried out in three stages:
1. Calculation of Dosing Channels Opening Percentage
To finely calibrate the FERTIKIT in order to achieve homogeneous and stable dosing, perform the following calculation
for each dosing channel (fertilizers and acid) to determine the amount of suction reduction needed to attain the
required fertilizer/acid flow rate.
2. Simulation Test with a 2 Gallon Bucket of Water
Instruments Needed
•Good-quality portable EC and pH sensors, finely calibrated
•Calibration solutions for EC and pH
•Bucket with a scale for up to 2 gallons
•Measuring tube or syringe with a scale for up to 1 ounce
•Clean (preferably distilled) water for cleaning sensors during calibration
•Blotting paper for cleaning and drying
The client prepares the fertilizer solutions and the acid solution (if required) in the stock tanks according to the recipe
advised by the agronomist/consultant.
ATTENTION
Ensure the fertilizers and acid solutions in the stock tanks have been thoroughly agitated before starting
the simulation.
NOTE
The visual flow meter's scale is calibrated by the manufacturer for measurement of the flow rate of water
(H2O). Certain inacuracies may be observed when the flow rate of liquids with different densities, such as
fertilizers and acids, is measured.
EXAMPLE
X 0.06 =
X
GPM
US gal/1000 US gal
GPH
GPH
X 1.25 =
500
15
45
56
US units
X 0.06 =
X
GPM
US gal/1000 US gal
GPH
GPH
X 1.25 =
Flow rate of the largest irrigation shift
Dosing ratio of a single fertilizer/acid
Result: a single fertilizer/acid flow rate
Result: target Rotameter reading
DEFINITION
Dosing ratio = The quantity of fertilizer/acid (l)
1 m3irrigation water
DEFINITION
Dosing ratio = The quantity of fertilizer/acid (US gal)
1 THG (1000 US gal) irrigation water
CALIBRATION