Raven DCS 300 Manual

DCS 300
INSTALLATION
AND
SERVICE MANUAL

N O T I C E
The use of the suspension type fertilizers and lime slurries will
significantly reduce the life of the plastic parts in the Flow
Meter and motorized Control Valve. Check the rotor and inlet hub
assembly in the Flow Meter frequently for worn parts. Excessive
wear can affect accuracy.
Do not attempt to modify or lengthen any of the three-wire Speed
Sensor or Flow Meter cables. Extension cables are available from
your Dealer.

Manual Rev. C, DCS 300, 10-97
Order: 50, 10-28-97, #016-0159-577

1
TABLE OF CONTENTS
SYMBOL DEFINITION .............................................................................................................................................. 2
INTRODUCTION....................................................................................................................................................... 3
INSTALLATION ......................................................................................................................................................... 4
1. MOUNTING THE ENCODER .............................................. 4
2. MOUNTING THE FLOW METER ........................................... 5
3. MOUNTING THE CONTROL VALVE ........................................ 6
4. MOUNTING THE CONSOLE AND CABLING .................................. 6
BATTERY CONNECTIONS...................................................................................................................................... 7
CONSOLE FEATURES ............................................................................................................................................ 8
CONSOLE CALIBRATION ....................................................................................................................................... 9
1. CALCULATING "METER CAL" ........................................... 9
2. CALCULATING "LIQ CAL" ............................................. 9
3. CALCULATING "GRAN CAL" ........................................... 11
4. VERIFYING "GRAN CAL" ............................................. 12
5. CALCULATING "VALVE CAL" .......................................... 13
CONSOLE PROGRAMMING ................................................................................................................................. 14
1. INITIAL CONSOLE PROGRAMMING ...................................... 15
2. OTHER DISPLAYS ................................................... 16
3. SELF TEST FEATURE ................................................ 16
INITIAL SYSTEM SET-UP ...................................................................................................................................... 17
INITIAL SYSTEM ROAD TEST .............................................................................................................................. 18
PREVENTIVE MAINTENANCE .............................................................................................................................. 18
APPENDIXES
1. ALTERNATE BY-PASS LINE PLUMBING SYSTEM......................................................................................... 19
2. PROCEDURE TO TEST FLOW METER/ENCODER CABLES........................................................................ 21
3. FLOW METER MAINTENANCE AND ADJUSTMENT PROCEDURE............................................................. 22
4. PROCEDURE TO RE-CALIBRATE FLOW METER .........................................................................................23
REPLACEMENT PARTS SHEETS
016-0159-577
10/97

2
SYMBOL DEFINITION
METER CAL CONVERSIONSMETER CAL CONVERSIONS
METER CAL CONVERSIONSMETER CAL CONVERSIONS
METER CAL CONVERSIONS
To convert the METER CAL number simply divide the original number (number printed
on Flow Meter label) by the desired conversion factor.
FOR EXAMPLE:FOR EXAMPLE:
FOR EXAMPLE:FOR EXAMPLE:
FOR EXAMPLE:
Original METER CAL No. = METER CAL No. for displays in Fluid OuncesFluid Ounces
Fluid OuncesFluid Ounces
Fluid Ounces
128
Original METER CAL No. = METER CAL No. for displays in LitersLiters
LitersLiters
Liters
3.785
Original METER CAL No. = METER CAL No. for displays in PoundsPounds
PoundsPounds
Pounds
Weight of one gallon
LIQUID CONVERSIONSLIQUID CONVERSIONS
LIQUID CONVERSIONSLIQUID CONVERSIONS
LIQUID CONVERSIONS
U.S. Gallons x 128 = Fluid Ounces
U.S. Gallons x 3.785 = Liters
U.S. Gallons x 0.83267 = Imperial Gallons
U.S. Gallons x 8.34 = Pounds (Water)
LENGTHLENGTH
LENGTHLENGTH
LENGTH
1 meter (m) = 3.281 feet
1 kilometer (km) = 0.621 mile
1 mile = 1.609 kilometers
PRESSUREPRESSURE
PRESSUREPRESSURE
PRESSURE
1 psi = 6.89 kPa
WEIGHTWEIGHT
WEIGHTWEIGHT
WEIGHT
1 pound = 0.454 kg
1 kg = 2.205 lbs
1 ton = 2000 lbs
1 metric ton = 1000 kg
gal - Gallons
lit - Liters
GPT - Gallons per ton
lit/MT - Liters per metric ton
PSI - Pounds per square inch
kPa - Kilopascal
lb/mile - Pounds per mile
kg/km - Kilograms per kilometer
lb - pounds
kg - kilograms
MPH - Miles per hour
km - Kilometers
km/h - Kilometers per hour
US - Volume in gallons
SI - Volume in liters
[] - Metric numbers

3
INTRODUCTION
The Raven DCS 300 (DE-ICE CONTROL SYSTEM) is designed to improve the uniformity of pre-
wetting applications automatically. Its performance relies on the installation and
preventive maintenance of the complete system. It is important that this Installation
and Service Manual be reviewed thoroughly before operating the system. This Manual
provides a simple step-by-step procedure for installing and operating the system.
The DCS 300 consists of a computer based Control Console, a Granular Encoder, a turbine
type Flow Meter, and a motorized Control Valve. The Console mounts directly in the cab
of the vehicle for easy operator use. The Granular Encoder is mounted on a granular
belt shaft. The motorized Control Valve and Flow Meter mount directly to the framework
of the spreader truck. Appropriate cabling is furnished for field installation.
The operator sets the target rate (volume per granular ton) to be applied and the DCS
300 automatically maintains the pre-wetting flow according to the actual granular
application rate (within range of selected spray nozzles). The DCS 300 additionally
functions as a volume totalizer and granular totalizer (up to 10,000 kg or lbs).

4
INSTALLATION
1. MOUNTING THE ENCODER
1)1)
1)1)
1) Mount Encoder on output shaft of conveyor or other shaft which rotates at a known
ratio to the conveyor.
2)2)
2)2)
2) Apply grease to Encoder shaft, conveyor shaft, and Encoder coupler (fits 1"
diameter conveyor shaft). Secure coupler to Encoder and conveyor shafts with set
screws provided.
3)3)
3)3)
3) Install mounting tabs to Encoder as shown in Figure 1. Connect mounting tab to
mounting bracket (not provided) to prevent Encoder from rotating. DO NOTDO NOT
DO NOTDO NOT
DO NOT rigidly
mount Encoder. Encoder is to be supported by coupler ONLY.
FIGURE 1
4

5
2. MOUNTING THE FLOW METER
l)l)
l)l)
l) Mount the Flow Meter in the area of the boom valve per Figure 2. All flow through
the Flow Meter must go to the boom valve only, i.e. no return line to tank or pump
after Flow Meter.
2)2)
2)2)
2) Mount Flow Meter horizontal to the ground. Use the bracket to secure the Flow
Meter.
3)3)
3)3)
3) For best results, allow a minimum of 7 1/2 inches [20cm] of straight hose on inlet
of Flow Meter. Bend radius of hose on outlet of Flow Meter should be gradual.
4)4)
4)4)
4) Flow must be in direction of ARROW on Flow Meter.
NOTE:NOTE:
NOTE:NOTE:
NOTE: For flow rates less than 3 GPM [11 lit/min], mount the Flow Meter
vertically with arrow pointing upward. (Refer to Appendix 1 for
alternate plumbing diagram).
NOTE:NOTE:
NOTE:NOTE:
NOTE: It is essential, when using suspensions, that the system be thoroughly
rinsed out each day after use. Failure to do so may cause system to
malfunction.
FIGURE 2FIGURE 2
FIGURE 2FIGURE 2
FIGURE 2
5

6
3. MOUNTING THE CONTROL VALVE
l)l)
l)l)
l) Mount the motorized Control Valve in the main hose line between the Flow Meter
and the boom valve, with motor in the upright position. (For less than 3 GPM [11
lit/min], the motorized Control Valve is mounted in the by-pass line, refer to
Appendix 1 for alternate plumbing diagram).
2)2)
2)2)
2) Connect the Flow Control Cable connector to the boom valve, Flow Meter, and
motorized Control Valve.
4. MOUNTING THE CONSOLE AND CABLING
l)l)
l)l)
l) Mount the Console to secure support inside the cab of the vehicle.
2)2)
2)2)
2) Connect the Console Control Cable to the plug in the back of the Console. Route
the cable out of the vehicle cab. (Flow Meter extension cables are available from
your Dealer).
3)3)
3)3)
3) Turn POWER switch OFF and route Red and White battery wires to a 12-Volt battery.
Attach White battery wire to the NEGATIVENEGATIVE
NEGATIVENEGATIVE
NEGATIVE (-) battery terminal, and the Red battery
wire directly to the POSITIVEPOSITIVE
POSITIVEPOSITIVE
POSITIVE (+) battery terminal. See Figure 4 on page 7. (DO(DO
(DO(DO
(DO
NOT CONNECT RED AND WHITE WIRES TO THE STARTER)NOT CONNECT RED AND WHITE WIRES TO THE STARTER)
NOT CONNECT RED AND WHITE WIRES TO THE STARTER)NOT CONNECT RED AND WHITE WIRES TO THE STARTER)
NOT CONNECT RED AND WHITE WIRES TO THE STARTER). Secure the battery wires with
plastic cable ties. DO NOTDO NOT
DO NOTDO NOT
DO NOT tie battery wires close to existing battery leads or
any other electrical wiring.
4)4)
4)4)
4) Connect the Encoder Sensor Cable to the plug in the back of the Console.
5)5)
5)5)
5) Secure and tie the Encoder Sensor Cable and Console Control Cable with plastic
cable ties.
6)6)
6)6)
6) Initial installation of the system is now complete.
FIGURE 3

7
BATTERY CONNECTIONS
FIGURE 4FIGURE 4
FIGURE 4FIGURE 4
FIGURE 4

8
Selects power ON or OFF.
CONSOLE FEATURES
IMPORTANT:IMPORTANT:
IMPORTANT:IMPORTANT:
IMPORTANT: This Console requires selection of USUS
USUS
US (gallons) or SISI
SISI
SI [liters]; and
C-SdC-Sd
C-SdC-Sd
C-Sd (Standard Valve) or C-FCC-FC
C-FCC-FC
C-FC (Fast Close Valve). Hold DAY VOLUME key to view
selections.
Console Revision can be determined by
letter stamped in REV box on label.
Console Program is determined by letter
stamped in PGM box on label.
Displays actual rate of application,
calibration, and function data.
ENTER -Used only to enter data into
the Console.
Alarm indicator light.
CE -Use like you do the CE key on a
calculator.
KEY SWITCH -Key must be in and turned
horizontal to enter data into Con-
sole. Key turned vertical and then
removed puts Console in operate mode.
See NOTE below.See NOTE below.
See NOTE below.See NOTE below.
See NOTE below.
CALIBRATION KEYS -- Used to enter data into the
Console to calibrate the system.
METER CAL -- Flow Meter Calibration Number
LIQ CAL -- Target Application Rate
GRAN CAL -- Determined by Encoder and System
FUNCTION KEYS -- Used to Display Data
DATA -- Turn Alarm ON/OFF
GRAN TOTAL -- Total Granular Applied
LIQ/GRAN -- Actual Application Rate
LIQ VOL/TANK -- Volume Remaining in Tank
SELF TEST -- Simulate Granular Output
TOTAL VOLUME -- Total Volume Applied
DAY VOLUME -- Total Volume Applied for Day
NOTE:NOTE:
NOTE:NOTE:
NOTE: The KEY SWITCH needs to be in the vertical position to allow operation of main
ON/OFF Valve or to turn the pump ON. The maximum rating of this switch is 4 AMPS.
If the main ON/OFF Valve or pump could draw current in excess of 4 AMPS, an external
relay must be added to prevent damage to the KEY SWITCH.

9
CONSOLE CALIBRATION
1. CALCULATING "METER CAL"
The Flow Meter calibration number is stamped on the tag attached to each Flow Meter.
This number is to be used for gallons [liters] per application.
To convert original METER CAL from gallons to desired units of measure, see METER
CAL CONVERSIONS on page 3. Write down this calibration number for future reference
when programming the Console.
2. CALCULATING "LIQ CAL"
Determine the application rate at which your chemical should be applied. Consult
with your Dealer to ensure your spray nozzles are capable of applying at this rate.
In determining which spray nozzles to use, you must know:
1) Nominal Application Pressure ___PSI [kPa]
2) Target Application Rate ___GPT [lit/MT]
3) Granular Application Rate ___(lb/mile) [kg/km]
4) Target Speed ___MPH [km/h]
5) Number Of Nozzles ___
From this information you can than calculate the volume per minute per nozzle as
follows:
GPM = GPT x (lb/mile) x MPH
120,000 (No. of nozzles)
lit/min = lit/MT x [kg/km] x [km/h]
60,000 (No. of nozzles)
Use GPM [lit/min] and pressure to select appropriate tip from tip chart.
EXAMPLE:EXAMPLE:
EXAMPLE:EXAMPLE:
EXAMPLE: 1) Application Pressure 30 PSI [200 kPa]
2) Target Application Rate 7.0 GPT [30 lit/MT]
3) Granular Application Rate 2900 lb/mile [800 kg/km]
4) Target Speed 6.2 MPH [10.5 km/h]
5) Number of nozzles 3
US UNITSUS UNITS
US UNITSUS UNITS
US UNITS GPM = 7.0 GPT x 2900 lb/mile x 6.2 MPH = .35 GPM
120,000 (3)
SI UNITSSI UNITS
SI UNITSSI UNITS
SI UNITS [lit/min] = 30 lit/MT x 800 kg/km x 10.5 km/h = 1.40 lit/min
60,000 (3)
Using CAPACITY = .35 GPM [1.40 lit/min] and pressure = 30 PSI [200 kPa] you would
select tip number XR8004 from the chart on next page, since it comes closest to
providing the desired output.

10
* Chart data from Spraying Systems Company
VERIFYING FLOW RATE LIMITS:VERIFYING FLOW RATE LIMITS:
VERIFYING FLOW RATE LIMITS:VERIFYING FLOW RATE LIMITS:
VERIFYING FLOW RATE LIMITS:
The total gallons per minute (GPM) [lit/min] flow rate of application must be
within the range of that specified for the Flow Meter.
FLOW METER MODEL FLOW RANGE
RFM 5 0.05-5 GPM [0.2-18.9 lit/min]
RFM 15 0.3-15 GPM [1.1-56.8 lit/min]
RFM 55/55A 1-55 GPM [3.8-208 lit/min]
RFM 100 3-100 GPM [11.4-379 lit/min]
RFM 200/200 Poly 15-200 GPM [56.8-757 lit/min]
RFM 400 25-400 GPM [94.6-1514 lit/min]

11
3. CALCULATING "GRAN CAL"
Factors which can affect the product GRAN CAL numbers are the product particle
size, density, temperature, and humidity. Always calibrate the material you have
purchased. Complete INITIAL CONSOLE PROGRAMMING, on page 15, before proceding
with this procedure. The GRAN CAL value is derived using the following procedure:
1)1)
1)1)
1) Place chalk mark or tape on granular belt shaft to use as a reference point.
2)2)
2)2)
2) Mark initial spot on the shaft in a convenient location.
3)3)
3)3)
3) Turn granular belt on, and allow to turn until a uniform amount of granular is
being applied.
4)4)
4)4)
4) Catch the granular from the belt for a period of 10 revolutions of the granular
belt shaft.
5)5)
5)5)
5) Weigh the amount of granular that was caught (lbs) [kg].
6)6)
6)6)
6) Divide 18,000 by this number. This is your GRAN CAL number. Write this number
down for future reference.
EXAMPLE:EXAMPLE:
EXAMPLE:EXAMPLE:
EXAMPLE: Weight of material caught = 90 lbs [40.8 kg]
ENGLISH UNITS:ENGLISH UNITS:
ENGLISH UNITS:ENGLISH UNITS:
ENGLISH UNITS: METRIC UNITS:METRIC UNITS:
METRIC UNITS:METRIC UNITS:
METRIC UNITS:
GRAN CAL = 18,000 = 200 18,000 = 441
90 [40.8]
GRAN CAL = 200 [441]
NOTE:NOTE:
NOTE:NOTE:
NOTE: This measurement is critical to the accuracy of the system..
..
. MEASUREMEASURE
MEASUREMEASURE
MEASURE
CAREFULLYCAREFULLY
CAREFULLYCAREFULLY
CAREFULLY. For best results, measure several times and average the
results. If for any reason the amount of granular on the belt changes
(i.e. the granular gate height is adjusted), the GRAN CAL number will
be invalid, and must be measured again.

12
4. VERIFYING "GRAN CAL"
To verify this GRAN CAL number, perform the following procedure:
1)1)
1)1)
1) Use a pre-weighed box to capture granules as they are metered out.
2)2)
2)2)
2) Enter the pre-determined GRAN CAL into key labelled:
3)3)
3)3)
3) Enter a "0" in key labelled:
4)4)
4)4)
4) Turn granular belt ON to begin collecting granules.
5)5)
5)5)
5) Turn granular belt OFF when GRAN TOTAL display reads 200.
6)6)
6)6)
6) Weigh the collected granules. If the actual weight is not 200 lbs, perform the
following calculation:
EXAMPLE:EXAMPLE:
EXAMPLE:EXAMPLE:
EXAMPLE: Old GRAN CAL = 200
GRAN TOTAL reading = 200
Weight of collected material = 128
Corrected GRAN CAL = Old GRAN CAL x GRAN TOTAL reading
Weight of collected material
= 200 x 200 = 312
128
Corrected GRAN CAL = 312
This is the new GRAN CAL value.
Enter this corrected GRAN CAL into key labelled:
Repeat this procedure (starting with Step 3) until the weight of the metered
material equals the value in the GRAN TOTAL display.

13
Valve Backlash DigitValve Backlash Digit
Valve Backlash DigitValve Backlash Digit
Valve Backlash Digit Controls the time of the first correction pulse
after a change in correction direction is detected.
(INC to DEC -or- DEC to INC).
Range: 1 to 9 1-Short Pulse
9-Long Pulse
Valve Speed DigitValve Speed Digit
Valve Speed DigitValve Speed Digit
Valve Speed Digit Controls response time of Control Valve motor.
CAUTION:CAUTION:
CAUTION:CAUTION:
CAUTION: Running the Control Valve too fast will
cause the system to oscillate.
C-Sd Valve Control Range: 1 to 9 1-Slow
9-Fast
C-F or C-FC Valve Control Range: 0 to 9 0-Fast
9-Slow
Brake Point DigitBrake Point Digit
Brake Point DigitBrake Point Digit
Brake Point Digit Sets the percent away from target rate at which the
Control Valve motor begins turning at a slower
rate, so as not to overshoot the desired rate.
Range: 0 to 9 0 = 5%
1 = 10%
9 = 90%
Dead-Band DigitDead-Band Digit
Dead-Band DigitDead-Band Digit
Dead-Band Digit Allowable difference between target and actual
application rate, where rate correction is not
performed.
Range: 1 to 9 1 = 1%
9 = 9%
4. CALCULATING "VALVE CAL"
The initial Control Valve calibration number for VALVE CAL is 2123 for C-Sd
(standard valve), or 743 for C-F (fast valve) and C-FC (fast close valve). The
VALVE CAL number is used to control response time of the Motor Control to the change
in vehicle speed. After operating the system, you may desire to refine this number.
See definitions below:
For FAST VALVEFAST VALVE
FAST VALVEFAST VALVE
FAST VALVE (C-F or C-FC):
For STANDARD VALVESTANDARD VALVE
STANDARD VALVESTANDARD VALVE
STANDARD VALVE (C-Sd):

14
CONSOLE PROGRAMMING
When entering data into the Console, the entry sequence is always the same.
NOTE:NOTE:
NOTE:NOTE:
NOTE: Data must be entered into keys 2, 3, & 4 with the key switch turned to
the horizontal position.
Depress the key in which
you wish to enter data. Depress the ENTER key. An "E" will illuminate in the
display.
Depress the keys correspond-
ing to the number you wish to
enter (i.e. "7","4","3").
The numbers will be dis-
played as they are entered.
Complete the entry by again
depressing the ENTER key.

15
1. INITIAL CONSOLE PROGRAMMING
When you first turn on Console power, after all installation procedures have been
completed, the Console will display "US" in the display window. This means you
must "calibrate" or program the Console before it can be operated. This is a one-
time operation which does not have to be repeated. Turning OFF the POWER ON/OFF
switch does not affect the Console memory. All data is retained in non-volatile
memory.
IMPORTANT:IMPORTANT:
IMPORTANT:IMPORTANT:
IMPORTANT: If an entry selection error is made during Steps 1-4, place the power
switch to the OFF position. Depress and hold while placing the power
switch to ON. This will "reset" the Console. The display will now show "US".
The following steps must be followed:
1)1)
1)1)
1) Display US (gallons) or SI (liters).
a) Depressing momentarily steps the display from US to SI.
b) Depressing momentarily steps the display from SI to US.
2)2)
2)2)
2) Selecting US or SI.
a) To select US or SI, step with until the desired code is displayed.
b) Momentarily depress . The display will now show C-Sd.
3)3)
3)3)
3) Display C-Sd (Standard Valve) or C-FC (Fast Close Valve).
a) Depressing momentarily steps the display from C-Sd to C-FC.
b) Depressing momentarily steps the display from C-FC to C-Sd.
4)4)
4)4)
4) Selecting C-Sd or C-FC.
a) To select C-Sd or C-FC step until desired code is displayed.
b) Momentarily depress . The display will now show CAL.
5)5)
5)5)
5) Enter METER CAL in key labelled:
6)6)
6)6)
6) Enter target LIQUID CAL application rate (GPT) [lit/MT] in key labelled:
NOTE:NOTE:
NOTE:NOTE:
NOTE: A decimal point is displayed automatically. Therefore, twenty gallons per
ton is entered as 20.0, not 2.0.
7)7)
7)7)
7) Enter initial GRAN CAL calibration number of 200 in key labelled:

16
YOU HAVE NOW COMPLETED PROGRAMMING THE CONSOLEYOU HAVE NOW COMPLETED PROGRAMMING THE CONSOLE
YOU HAVE NOW COMPLETED PROGRAMMING THE CONSOLEYOU HAVE NOW COMPLETED PROGRAMMING THE CONSOLE
YOU HAVE NOW COMPLETED PROGRAMMING THE CONSOLE
The flashing "CAL" will now extinguish. If not, repeat procedure starting at
Step 5. You may also wish to enter data in the key labelled: although it
is not required for the operation of the system.
8)8)
8)8)
8) Enter the estimated TOTAL VOLUME in TANK before you start applying product
in key labelled: Each time the tank is refilled, this number must be
re-entered.
9)9)
9)9)
9) To change VALVE CAL calibration number depress key labelled: for 5
seconds. Display will flash. Enter VALVE CAL number. (See page 13 for default
VALVE CAL settings).
NOTE:NOTE:
NOTE:NOTE:
NOTE: To display operating mode (US, SI), and valve control (C-Sd, C-FC), depress
key labelled: for 5 seconds and continue holding.
2. OTHER DISPLAYS
1)1)
1)1)
1) To display your actual application rate, LIQ per TON, momentarily depress key
labelled:
2)2)
2)2)
2) To display TOTAL GRANULAR applied (lb) [kg], momentarily depress the key
labelled: To "zero out" this total at any time, enter a "0" in this key.
3)3)
3)3)
3) To display LIQUID VOLUME remaining in TANK (gal) [lit], momentarily depress
key labelled:
4)4)
4)4)
4) To display liquid TOTAL VOLUME applied, momentarily depress key labelled:
To "zero out" this total at any time, enter a "0" in this key.
5)5)
5)5)
5) To display liquid DAY VOLUME applied, momentarily depress key labelled:
To "zero out" this total at any time, enter a "0" in this key.
3. SELF TEST FEATURE
SELF TEST allows granular application simulation for testing the system while the
vehicle is not moving. Enter the simulated operating granular rate by depressing
the key labelled: (display will flash). If 600 lbs/mile [kg/km] is
desired, enter 600 [600]. (See CONSOLE PROGRAMMING on page 14).
NOTE:NOTE:
NOTE:NOTE:
NOTE: The SELF TEST feature assumes a vehicle speed of 20 MPH [km/h].