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CapstanAG Synchro Operator's Manual

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TM
Synchro™
Spray Application
Operator Manual
113100-596 Rev. A | Revised 08/2021 | ©2021 Capstan Ag Systems, Inc.

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  • Page 1 Synchro™ Spray Application Operator Manual 113100-596 Rev. A | Revised 08/2021 | ©2021 Capstan Ag Systems, Inc.
  • Page 2 Thank you for your business! At CapstanAG, our goal is to redefine the way people do their chemical application. Our PWM control systems have been setting the bar for maximum productivity for more than 20 years. Our focus on performance, support, and education have dramatically changed the landscape of agricultural chemical application.

  • Page 3: Table Of Contents

    Make a profile on the Internet....................17 Make a Profile on the Controller Wi-Fi..................18 Transmit a Profile........................19 Spray with the CapstanAG System..................20 Spray without the CapstanAG System (Manual Mode)............21 Chapter 6: Maintenance..............23 Service the System........................23 Jump Start, Weld On, or Charge the Machine.............. 23 Recommended Guidelines for Maintenance/Service..............23...
  • Page 4 Winterize for Storage..................... 26 Chapter 7: Troubleshooting............... 27 Troubleshooting Charts......................27 Interchange the Components....................29 Nozzle Valves........................... 30 Clean the Nozzle Valve(s)..................... 30 Plunger Seal Inspection....................31 System Dry Test........................32 System Wet Test........................33 Coil Assembly Test........................34 Do a Check of the System Load Capacity................34 Battery Voltage Test.........................

  • Page 5: Chapter 1: Safety

    Very small fires can be put out (extinguished) with a fire extinguisher. Use an appropriate method to extinguish a fire (water for paper fires, and chemical extinguishers for electrical or chemical fires). © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 6: Personal Protective Equipment

    Keep sparks and flames away from the battery. Battery gas can explode and cause serious injury. Do not smoke in the battery charging area. Remove jewelry, which might make electrical contact and create sparks. © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 7: Chapter 2: Warranty

    The terms of this warranty do not in any way extend to any product which was not manufactured by us or one of our affiliates. While necessary maintenance or repairs on your CapstanAG product can be performed by any company, we recommend that you use only authorized CapstanAG dealers. Improper or incorrectly performed maintenance or repair voids this warranty.
  • Page 8 This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Rev. Date 7/15/2014 © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 9: Chapter 3: Introduction

    Please keep this manual and all enclosed documentation in an accessible location known to all operators, installation, and maintenance personnel. If you do not understand the CapstanAG equipment after reading this manual, please obtain the proper training before working with equipment, to make sure that your own safety, as well as your co- workers’...

  • Page 10: System Identification

    If you are not the original owner of this machine, it is in your interest to contact your local CapstanAG dealer to inform them of this unit's serial number. Providing this information will help CapstanAG notify you of any issues or product improvements.

  • Page 11: Chapter 4: Installation

    Installation Chapter 4: Installation Prepare for Installation If the CapstanAG system has been installed on the sprayer, continue with this manual. ™ If the CapstanAG system has not been installed yet, go to the Synchro Installation Guide for correct installation procedures.

  • Page 12: System Dry Test

    Figure 2: Make sure that the sprayer is off. On the cab box (1), toggle the red Synchro switch (2) to ON. The LED (3) in the switch will illuminate. The system should come with an active profile from the factory.

  • Page 13: System Wet Test

    Figure 3: Use water to pressurize the system. On the cab box (1), toggle the red Synchro switch (2) to ON. The LED (3) in the switch will illuminate. The system should come with an active profile from the factory.
  • Page 14 Installation © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 15: Chapter 5: Operation

    Operation Chapter 5: Operation Website The website, https://orchard.capstanag.com, is where you build or change profile information for your sprayer. Figure 4: The system configuration interface includes: Item Name Description Profile Name Name the profile for the sprayer Download Profile When all of the information is correct (no red errors showing), click Download Profile.
  • Page 16 If the system has one tip per valve use 10 Hz. If the system has multiple tips per valve use 3 Hz. For additional information, contact your CapstanAG representative for specific settings. Change Flow Allows you to change the flow nozzle by nozzle...

  • Page 17: Make A Profile On The Internet

    If you are using a device that is not portable, you will need to be able to transfer the profile to a portable device like a tablet, phone, or laptop computer. Go to https://orchard.capstanag.com. Enter the correct information for your sprayer.

  • Page 18: Make A Profile On The Controller Wi-Fi

    Operation Make a Profile on the Controller Wi-Fi Figure 5: On the machine/sprayer, toggle the red Synchro switch (1) to on. The light on the switch will illuminate. On your device, connect to the SNCHRO 209XXXX WI-FI. The XXXX shown above will be the last 4 digits of the controller serial number.

  • Page 19: Transmit A Profile

    Operation Transmit a Profile Figure 6: On the machine/sprayer, toggle the red Synchro switch (1) to on. The light on the switch will illuminate. On your device, connect to the SNCHRO 209XXXX WI-FI. The XXXX shown above will be the last 4 digits of the controller serial number.

  • Page 20: Spray With The Capstanag System

    Important: If any switch is ON the system will still pull a current that can drain the battery. Note: If one or both boom switches are ON but the Synchro switch is OFF, the system will operate with a constant equal flow of product through all nozzles and not use the profile parameters.

  • Page 21: Spray Without The Capstanag System (Manual Mode)

    Operation Spray without the CapstanAG System (Manual Mode) Spraying without the CapstanAG System can be used to flush the system out, or can be used to spray conventionally, especially during a failure. Spray without using the CapstanAG system if necessary to complete a job when there is a failure in the system.
  • Page 22 Operation © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 23: Chapter 6: Maintenance

    Clean the System Clean the Strainers and Screens Clean the Nozzle Valves and Inspect the Plungers Storage of the System Details for each of these procedures are following in this section of the manual. © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 24: Baseline Evaluation Process

    When replacing the mesh screen on a Tee-jet Strainers: Install and set the mesh screen in the strainer head. Install the strainer cap. Important: Failure to do this will likely result in a damaged mesh screen and overall strainer failure. © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 25: Clean The Nozzle Valve(S)

    The result is erratic pulsing, often described as “flickering.” The system will operate normally at lower pressures until replacement parts can be installed. High operating pressures and abrasive chemicals will accelerate the wear of the plunger seal material. © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 26: Storage Of The System

    Winterize the system with RV antifreeze for winter storage. Proper winterizing of the machine with a CapstanAG system installed on it is essential. Make sure that the lines are completely full of antifreeze at 100% strength and that the nozzle valves are purged until 100% antifreeze is seen at all nozzle valves.

  • Page 27: Chapter 7: Troubleshooting

    Bleed air from the system Faulty pressure sensor Replace the pressure sensor Speed too slow Increase speed Speed too fast Slow down Pressure too low Increase the pressure Pressure too high Decrease the pressure © ™ 2021 Capstan Ag Systems, Inc. Synchro...
  • Page 28 Coil not operating Do a check of the coil and replace as necessary Synchro Switch Not illuminating No power to cab box or system Make sure the system is when in the on position. connected to a 12 V power...

  • Page 29: Interchange The Components

    I get one or many Error: Did not receive Move closer to the machine and try again. If that expected response when trying to transmit a does not work turn the Synchro switch to off, profile. wait five seconds, turn the switch on then try to transmit again.

  • Page 30: Nozzle Valves

    Important: Do not use brake cleaner. Brake cleaner can damage the seal. Important: During installation, apply 40 lbf in (4.52 Nm) of torque to the coil when it threads into the valve body to properly seat the O-ring. © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 31: Plunger Seal Inspection

    The result is erratic pulsing, often described as “flickering.” The system will operate normally at lower pressures until replacement parts can be installed. High operating pressures and abrasive chemicals will accelerate the wear of the plunger seal material. © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 32: System Dry Test

    Figure 11: Make sure that the sprayer is off. On the cab box (1), toggle the red Synchro switch (2) to ON. The LED (3) in the switch will illuminate. The system should come with an active profile from the factory.

  • Page 33: System Wet Test

    Figure 12: Use water to pressurize the system. On the cab box (1), toggle the red Synchro switch (2) to ON. The LED (3) in the switch will illuminate. The system should come with an active profile from the factory.

  • Page 34: Coil Assembly Test

    If low voltage is observed, do a check of: • The battery terminals and clean as necessary • The condition of the battery • The condition of the alternator • The condition of the connections © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 35: Battery Voltage Test

    If there is no voltage present between pin A (PWR +) and pin C (GND -) or pin B (PWR +) and pin D (GND -), do a check of: • The 20A fuses (1) on the power harness • The condition of the battery, battery harness, ring terminals, and alternator © ™ 2021 Capstan Ag Systems, Inc. Synchro...
  • Page 36 Troubleshooting © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 37: Chapter 8: Schematics

    System Layout Figure 14: Callout Description Callout Description Control Module Cab Box Harness Power Harness Cab Box Battery Harness Cab Box Extension Harness Valve Harness 2-pin WP Tower Dust Plug Valve Assembly © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 38: Parts List

    Distance from the control box to nozzles is less than 15 ft Part Number Description Drawing Description 113100-550 16-drop Valve Harness—15 ft 16 Drop Valve Harness, 15ft Synchro Orchard 113100-551 9-drop Valve Harness—15 ft 9 Drop Valve Harness, 15ft Synchro Orchard...
  • Page 39 Installation Guide Installation Guide, Synchro Orchard 113100-596 Operator Manual Operators Manual, Synchro Orchard 113100-597 Quick Start Guide Quick Start Guide, Synchro Orchard 113100-590 Mounting Kit Mounting Kit—RAM cabbox mount, and custom controller mounting bracket 116200-045 2-pin WP Tower Dust Plug...

  • Page 40: Control Module Pinout

    Table 7: POWER Connector (1) Pinout—8-pin DT Receptacle Color Color Plug Black Plug Black Plug Plug Table 8: INPUT Connector (2) Pinout—14-pin DT Receptacle Color Color Plug Violet Plug Yellow Plug Pink Plug Brown Plug Black Plug Plug Plug © ™ 2021 Capstan Ag Systems, Inc. Synchro...
  • Page 41 Blue/Orange Table 10: RIGHT Connector (4)Pinout—35-pin AMP Connector Color Color Red/White Yellow/Orange Red/White Yellow/Orange Black/White Green/Orange Black/White Green/Orange Blue/White Brown/Orange Blue/White Brown/Orange Yellow/White White/Red Yellow/White White/Red Green/White White/Black Green/White White/Black Brown/White White/Blue © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 42: Cab Box Harness Pinout

    Table 11: 14-pin AMP Plug Connector Pinout (1) Color Color Plug Violet Plug Yellow Plug Pink Plug Brown Plug Black Plug Plug Plug Table 12: 6-Pin DT Plug Connector Pinout(2) Color Color Pink Violet Brown Yellow Black © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 43: Power Harness Pinout

    Power Harness Pinout Figure 17: Table 13: 8-Pin AMP Plug Connector Pinout (1) Color Color Plug Black Plug Black Plug Plug Table 14: 4-Pin Tower WP Connector Pinout (2) Color Color Black Black © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 44: Battery Harness Pinout

    The power (Red) wire (1) has two 20 A fuses (2) and connects to the positive power terminal. The ground (black) wire (3) connects to a ground. Table 15: The 4-pin WP Shroud connector (4) Color Color Red (Fuse 1) Black Red (Fuse 2) Black © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 45: Valve Harness

    Yellow/Orange Black/White Green/Orange Black/White Green/Orange Blue/White Brown/Orange Blue/White Brown/Orange Yellow/White White/Red Yellow/White White/Red Green/White White/Black Green/White White/Black Brown/White White/Blue Brown/White White/Blue Red/Orange White/Orange Red/Orange White/Orange Black/Orange Plug Black/Orange Plug Blue/Orange Plug Blue/Orange © ™ 2021 Capstan Ag Systems, Inc. Synchro...
  • Page 46 Table 23: 2-Pin WP Shroud Connector Pinout (8) Color Color Red/Orange Red/Orange Table 24: 2-Pin WP Shroud Connector Pinout (9) Color Color Black/Orange Black/Orange Table 25: 2-Pin WP Shroud Connector Pinout (10) Color Color Blue/Orange Blue/Orange © ™ 2021 Capstan Ag Systems, Inc. Synchro...
  • Page 47 Table 30: 2-Pin WP Shroud Connector Pinout (15) Color Color White/Black White/Black Table 31: 2-Pin WP Shroud Connector Pinout (16) Color Color White/Blue White/Blue Table 32: 2-Pin WP Shroud Connector Pinout (17) Color Color White/Orange White/Orange © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 48: Valve Harness-9 Valves Pinout

    Plug Black/White Plug Black/White Plug Blue/White Plug Blue/White Plug Yellow/White Plug Yellow/White Plug Green/White Plug Green/White Plug Brown/White Plug Brown/White Plug Red/Orange Plug Red/Orange Plug Black/Orange Plug Black/Orange Plug Blue/Orange Plug Blue/Orange © ™ 2021 Capstan Ag Systems, Inc. Synchro...
  • Page 49 Table 40: 2-Pin WP Shroud Connector Pinout (8) Color Color Red/Orange Red/Orange Table 41: 2-Pin WP Shroud Connector Pinout (9) Color Color Black/Orange Black/Orange Table 42: 2-Pin WP Shroud Connector Pinout (10) Color Color Blue/Orange Blue/Orange © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 50: Nozzle Valve Assembly

    Schematics Nozzle Valve Assembly Figure 21: Item Description Part Number Item Description Part Number Coil 625147-011 O-ring 715022-204 Plunger 716009-111 Valve Body 621083-001 © ™ 2021 Capstan Ag Systems, Inc. Synchro...

  • Page 51: Index

    Service the System Chemical Safety Signal Words Clean the Nozzle Valves Spray with the CapstanAG System Clean the System Spray without the CapstanAG System (Manual Mode) Coil Assembly Test Connect the machine Storage of the System Control Module Pinout Strainers and Screens...
  • Page 52 Index © ™ 2021 Capstan Ag Systems, Inc. Synchro...
  • Page 54 Application Systems for Professionals™ prodsupport@capstanag.com | 855-628-7722 | www.capstanag.com ©2021 Capstan Ag Systems, Inc. All Rights Reserved. | All trademarks are owned by Capstan Ag Systems, Inc. This product may be covered by one or more U.S. Patents. For more information go to www.BlendedPulse.com...

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