Netaflex™ 3G Installation Manual
Contents
1. a NETAFIM V 001 01 AUGUST 2013 COPYRIGHT 2013 NETAFIM NO PARTS OF THIS PUBLICATION MAY BE REPRODUCED STORED IN AN AUTOMATED DATA FILE OR MADE PUBLIC IN ANY FORM OR BY ANY MEANS WHETHER ELECTRONIC MECHANICAL BY PHOTOCOPYING RECORDING OR IN ANY OTHER MANNER WITHOUT PRIOR WRITTEN PERMISSION OF THE PUBLISHER ALTHOUGH NETAFIM TAKES THE GREATEST POSSIBLE CARE IN DESIGNING AND PRODUCING BOTH ITS PRODUCTS AND THE ASSOCIATED DOCUM NETAFIM WILL NOT ACCEPT RE THE USE OF THIS MANUAL NETAFIM RESERVES THE RIGHT ENTATION THEY MAY STILL INCLUDE FAULTS SPONSIBILITY FOR DAMAGE RESULTING FROM THE USE OF NETAFIM S PRODUCTS OR TO MAKE CHANGES AND IMPROVEMENTS TO ITS PRODUCTS AND OR THE ASSOCIATED DOCUMENTATION WITHOUT PRIOR NOTICE Jm FOREIGN LANGUAGES In the event that you a acknowledge and agre re reading this manual in a language other than the English language you e that the English language version shall prevail in case of inconsistency or contradiction in interpretation or translation CONTENTS Use of symbols Introduction General instructions Safety instructions When using acid chemicals Description Introduction Highlights Advantages Specifications Basic functions Operating principle Service Maintenance Add ons Schematic diagram Typic2. Basic functions The NetaFlex 3G supports the following Nutrigation functions e Fully controlled dosing and mixing of fertilizers acid with source water into a homogenous nutrient solution e EC and pH correction of the nutrient solution single or dual EC and pH control available Operating principle Fertilizers and acid are injected into a tank opened to the atmosphere a homogeneous solution is prepared in the tank before it is delivered to the field The open mixing tank method permits accelerated assimilation of fertilizers into the water The result is a perfectly mixed solution Service The NetaFlex 3G utilises a modular construction making servicing a simple and prompt process The dealer keeps a small quantity of interchangeable components on hand for replacement on site within a few minutes Maintenance To prevent failures and extend the life cycle of the NetaFlex 3G regular maintenance must be carried out by the user such as periodic rinsing of filters and calibration of the EC and pH sensors Regular maintenance of the NetaFlex 3G is a prompt low cost process requiring no special tools or skils 10 NETAFLEX 3G INSTALLATION MANUAL DESCRIPTION Add ons You can extend the functionality of your NetaFlex 3G by means of the many add ons offering a wide variety of useful functions All the add ons are easy to connect to the NetaFlex 3G here are a few examples Fertilizer meter with e
3. 355 Ibs CM15 2 160 kg 353 Ibs CM25 2 172 kg 379 Ibs CR32 2 2 214kg CR32 2 CR45 2 2 CR64 2 2 226 kg 472 lbs 498 Ibs 280 kg 617 lbs 233 kg 279 kg 615 lbs 514 Ibs 291 kg 642 Ibs 290 kg 639 Ibs 356 kg 785 Ibs 410 kg 904 Ibs 363 kg 800 Ibs 409 kg 902 Ibs 296 kg 653 Ibs 426 kg 939 Ibs NETAFLEX 3G INSTALLATION MANUAL 13 ON SITE PREPARATIONS Hydraulic infrastructure preparation Before performing the infrastructure installation consult Typical installation overview page 12 Required proportions To enable optimal operation of the NetaFlex 3G piping must be installed while maintaining the following proportions Fig 3 NetaFlex 3G Table 4 Infrastructure required proportions Description Required proportions Filling line pipe diameter e 40 mm 1 for dosing channels of over 400 I hr 106 GPH Length of the pipe upstream from the water meter to the adjacent corner 10x D e Pipe must be straight X Length of the pipe downstream from the water meter to the adjacent corner 5 x D e Pipe must be straight Fertilizer acid lines pipe diameter e 32 mm 114 for dosing channels of up to 400 I hr 106 GPH Length of fertilizers or acid lines Max 10 meter 33 feet Elevation of the fertilizer acid tanks Min 30 cm 12 Filling line flow rate and pressure requirements In order to enable the Ne
4. Define the dosing configuration while the EC and pH controls are in the OFF position NMC Pro screen 7 7 In the EC and pH alarm definitions set the EC and pH alarm to the OFF position deactivated NMC Pro screen 3 6 Enter the data for the irrigation valves and the dosing ratio for each dosing channel NMC Pro screens 1 1 1 2 1 3 Run the program NMC Pro screen 2 2 Allow a few minutes for the pipes to fill up and the flow rate to stabilize Reduce the suction of the dosing channels by adjusting the manual needle valve of each dosing channel until the target Rotameter reading calculated in stage 1 page 24 is attained NOTE The Rotameter s sacle 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 Check the appropriate controller screen for the measured EC and pH values NMC Pro hot screen 4 If the desired values have been reached check opening percentages of the dosing valves The EC and pH target values should be attained with the dosing valves opened to 50 80 of their capacity If the EC and pH target values are attained with the dosing valves opened less than 50 reduce the dosing channel suction rate until the EC and pH target values are reached NOTE Every change in the flow rate of the needle valve must be updated afterwards in the c
5. QJ Fertilizer acid filter lt 130 um 120 mesh 9 Water meter With electrical pulses The pulse should be as short as possible according to the output line diameter and the controller s limitations See Recommended flow meter table 8 below Jm CAUTION EC and pH sensors must never be exposed to pressure greater than 6 bars 87 PSI Table 7 Recommended flow meter pulse rate Flowrate Flow meter output Flow rate Flow meter output m hr I pulse GPM US gal pulse The fertilizer acid tanks and lines For the setup of the fertilizer acid tanks and lines the following components should be installed Table 8 Components of the fertilizer acid tanks and lines B Fertilizer acid stock tank l Between 1 and 6 fertilizer acid solution stock tanks 9 Manual valve fertilizer A manual ball valve on each fertilizer acid line at the stock tank outlet QJ Fertilizer acid filter 130 um 2 120 mesh The following aspects should be taken into account Ensure the stock tanks are of sufficient size for storage of at least one day s consumption Sufficient space should be available between the fertilizer acid tanks and the NetaFlex 3G to enable inspection and maintenance operations e Fertilizer acid pipe diameter 32 mm 1 A for dosing channels of up to 400 I hr 106 GPH 40 mm 1 for dosing channels of over 400 I hr 106 GPH For the connection of fertilizer supply lines to the NetaFlex 3G use a transparent chemi
6. The water level in the tank is kept Perform a simulation test with a 10 liter 2 gallons bucket of water see Appendix 1 Calibration page 24 NETAFLEX 3G INSTALLATION MANUAL 21 SYSTEM OPERATION Check the system pump operation CAUTION Only qualified electricians are permitted to perform electrical installations and repairs Switch the system pump ON for a few seconds and check that it is rotating in the correct direction If the pump does not rotate in the correct direction a qualified electrician should swap between phases L1 and L3 see the system pump Manual AN HIGH VOLTAGE ELECTRICAL HAZARD Before unplugging the system from the main power source switch the unit and the main power source OFF Running the NetaFlex 3G Define a program in the controller for one valve or multiple valves shift as defined by the irrigation plan see the Controller Manual In the first stage it is recommended that you define a program with quantitative or proportional fertigation only without EC pH control see the Controller Manual Temporarily deactivate all alarms in the system EC pH flow control etc see the controller manual Start the program and wait for the lines to be filled this takes a few minutes depending on the size of the installation Check that the flow rate displayed on the controller s screen and the pressure at the system outlet displayed on the pressure gauge are stabilized see the Controller Manu
7. Rotameter DFM170 15 150 I hr 4 40 GPH 77540 007575 Rotameter DFM170 40 400 I hr 10 6 106 GPH 77540 007570 Rotameter DFM185 60 600 I hr 15 8 158 GPH 77540 007577 FSP Dosing channel connection between Suitable for dosing channels Ro istretarand needle valve DEMT70 501 h 13 GPH 1501 h 40 GPH 33240 004350 10 05 and 4001 h 106 GPH FSP Dosing channel connection between Suitable for dosing channels l Rotameter and needle valve DFM185 600l h 158 GPH 33240 004400 EI Needle valve RPRV 1 2 FPM 10001 h 265 GPH 77500 004850 FSP Dosing channel connection between pil Die Tor Coste comics 10 07 needle valve and dosing valve S12 BANAT aE GPA Saco Oma te 9 with dosing valve Fip 12 Suitable for dosing channels MIET Dosing valve S12 600 I h 158 GPH 77540 008480 10 09 7 10 11 10 12 Venturis Table 14 Part Description carn ERIT Venturi PVDF M50 33240 003200 SPAI Venturi PVDF M50 Dual 33220 003210 NETI Venturi PP N150 33240 002300 LTI Venturi PVC N600 33240 002370 Kil Venturi PVC N600 Dual 33240 002375 i HI coor em Sra a me 34 NETAFLEX 3G INSTALLATION MANUAL APPENDIX 2 SYSTEM PUMP LIST System pump list Table 15 For 50 Hz installations Table 16 For 60 Hz installations Pump Electrical data Pump Electrical data Rated power P2 2 2 kW Rated power P2 2 5 kW Rat
8. during the warranty period contact your local Netafim representative Limited warranty This warranty is subject to the conditions in Netafim s official warranty statement For the full text of Netafim s official warranty statement please contact your local Netafim representative NETAFLEX 3G INSTALLATION MANUAL 29 yl 7 y APPENDIX 1 NetaFlex 3G PARTS LIST Fig 13 100 L Horizontal Pump See Parts list table 12 page 32 30 NETAFLEX 3G INSTALLATION MANUAL APPENDIX 1 NetaFlex 3G PARTS LIST Fig 14 200 L Vertical Pump See Parts list table 12 page 32 r f A fl i i A 7 A f LI ra Re J I ike 4 we as NETAFLEX 3G INSTALLATION MANUAL 31 APPENDIX 1 NetaFlex 3G PARTS LIST Table 12 Main parts described in figures 13 14 pages 30 31 Description Cat No Frame for NetaFlex M 3G J_ Control unit L Water Tank 100L black 55cm diam 57cm high Water Tank 200L black 55cm diam 114cm high System Inlet Float Valve Float valve to tank adaptor 4 Difuser Kit Lower manifold to tank adaptor i Inlet to pump 6 2 ih Outlet from pump adaptor 7 7 Outlet from pump manifold i Check valve Per NetaFlex 3G Serial Number 71177 Outlet from check valve i Outlet from pump manifold to filter adaptor Th Filter ij Filter to upper mani
9. rate I hr I hr X 1 25 X 1 25 Result target Rotameter reading hr I hr DEFINITION Mi l l The quantity of fertilizer acid I Dosing ratio 1 m irrigation water US units EXAMPLE Flow rate of the largest irrigation shift _ GPM GPM X X Dosing ratio of a single fertilizer acid US gal 1000 US gal US gal 1000 US gal X 0 06 X 0 06 Result a single fertilizer acid flow rate JGPH X 1 25 Result target Rotameter reading _ GPH DEFINITION Dosing tie The quantity of fertilizer acid US gal 1 THG 1000 US gal irrigation water NOTE The Rotameter s sacle is calibrated by the manufacturer for measurement of the flow rate of water H20 Certain inacuracies may be observed when the flow rate of liquids with different densities such as fertilizers and acids is measured 2 Simulation test with a 10 liter 2 US gal bucket of water Instruments needed e Good quality portable EC and pH sensors finely calibrated e Calibration solutions for EC and pH e Bucket with a scale for up to 10 liters 2 US gallons e Measuring tube or syringe with a scale for up to 100 cc 1 oz e Clean preferably distilled water for cleaning sensors during calibration e 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 yo ATTENTION Ensure the fertilizers and ac
10. the NetaFlex 3G control cycle for pH Run the NetaFlex 3G with fresh water only until the pH value stabilizes on the transducer s display Deviation not greater than 0 1 0 1 Manually open the acid dosing channel and simultaneously start a timer Observe the pH value on the transducer s display as soon as it first reacts stop the timer We recommend to repeat the 3 previous steps 3 times and calculate the average time Enter the data into the controller NMC Pro screen 7 7 Stop the program Time aplicable for EC and pH control cycle po ATTENTION Restore the settings of all the alarms back to the state where adequate protection to the system and the crop is provided see the Controller Manual If there is any problem during the process see Troubleshooting in the NetaFlex V 3G User Manual NETAFLEX 3G INSTALLATION MANUAL 23 CALIBRATION The process of calibrating the NetaFlex 3G is carried out in three stages 1 Calculation of dosing channels opening percentage To finely calibrate the NetaFlex 3G 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 Metric units EXAMPLE Flow rate of the largest irrigation shift ms hr m hr X X Dosing ratio of a single fertilizer acid I ms I ms Result a single fertilizer acid flow
11. Rated voltage 3 x 400A V Rated voltage 3x 440A V CR 45 2 voltage 3 x CR 45 2 2 Rated voltage 3 x 440A V l Nominal current 14 4 A l Consumption 11 15 kW Rated power P2 11 kW CR 64 24 Rated voltage 3 x 400A V Nominal current 14 2 A Consumption 7 65 kW Rated power P2 11 kW Rated voltage 3 x 440A V Nominal current 20 8 A oe Consumption 11 15 kW Rated power P2 11 kW Rated voltage 3 x 400A V Nominal current 20 8 A Consumption 11 15 kW Rated power P2 5 5 kW cee eI UN Consumption 5 65 kW Rated power P2 15 kW CR 64 2 2 Rated voltage 3 x 440A V Nominal current 10 6 A Rated power P2 7 5 kW CR 32 2 aoe voltage 3 x 440A V Consumption 7 65 kW CR 64 2 Nominal current 20 8 A Nominal current 28 0 A Consumption 11 15 kW Consumption 15 5 kW Total power consumption of the NetaFlex 3G with the mentioned system pump the controller the dosing valves etc NETAFLEX 3G INSTALLATION MANUAL 35 WWW NETAFIM COM
12. al Make sure flow rate and pressure are in range according to the performance curve of the relevant system pump see Sales Documentation page 10 Fig 10 If the system cannot reach the required flow rate and pressure it is possible that there is an air pocket in the system pump s impeller chamber Loosen the system pump s bleeding screw and wait until a stable flow free of air bubbles is obtained then retighten the bleeding screw see the System Pump Manual Check the suction of the dosing channels from the stock tanks and tune the desired flow rate for each dosing channel by adjusting the needle valve see Calibration of the dosing unit while irrigating page 26 Let the system run for about ten minutes and see that it works properly check for leaks in the NetaFlex 3G and the infrastructure After tuning the flow rate for each dosing channel adjust the cursors on each Rotameter Fig 10 NOTE The Rotameter s scale is calibrated by the manufacturer for measurement of the flow rate of water H20 Certain inacuracies may be observed when the flow rate of liquids with different densities such as fertilizers and acids is measured 22 NETAFLEX 3G INSTALLATION MANUAL SYSTEM OPERATION Measure the EC and pH control cycle e EC and pH control cycle is the time elapsed from the start of fertilizer or acid injection until the change starts to be recorded by the EC and pH transducer usually 4 10 sec To measure
13. al installation overview Dimensions Weights On site preparations Hydraulic infrastructure preparation Electrical preparation Installation Unpacking and placement Hydraulic installation Electrical installation System operation Preparations for running the NetaFlex 3G Running the NetaFlex 3G Calibration Calculation of dosing channels opening percentage Simulation with a 10 liter 2 US gal bucket of water Calibration of the NetaFlex 3G while irrigating Commissioning Warranty Appendices Appendix 1 NetaFlex 3G parts list Appendix 2 System pump electrical data 4 NETAFLEX 3G INSTALLATION MANUAL 6 CO NWN 29 30 35 TABLES FIGURES AND DIAGRAMS Tables CO co J O GI I wh Diagrams 1 2 3 Dosing channels for acid NetaFlex 3G dimensions NetaFlex 3G weights Hydraulic infrastructure required proportions Location of connectors Components of the water distribution system Recommended flow meter pulse rate Components of the fertilizer acid tanks and lines Mains wire size for three phasic system NetaFlex inlet outlet types of connectors Fertilizer acid lines types of connections Parts list Main parts Parts list Dosing channel parts Parts list Venturis Parts list System pumps for 50 Hz installations Parts list System pumps for 60 Hz installations Typica
14. binations that should never be used in the dual dosing channel as they will induce crystalization and cause clogging of the pipes Calcium Nitrate Ammonium Sulfate gt Calcium Sulfate e Calcium Nitrate Potassium Sulfate gt Calcium Sulfate e MKP Calcium Nitrate gt Calcium Phosphate e MAP Calcium Nitrate gt Calcium Phosphate e Phosphoric acid Calcium Nitrate gt Calcium Phosphate In case of doubt regarding the use of any combination of fertilizers in the dual dosing channel consult your local Netafim representative Electrical installation Jm CAUTION Only qualified electricians are permitted to perform electrical installations Have a qualified electrician connect the NetaFlex 3G to the mains Follow the instructions in the enclosed Swichboard Documentation 20 NETAFLEX 3G INSTALLATION MANUAL SYSTEM OPERATION NOTE The following procedure describes the operations that should be performed regardless of the type of controller in use For the operation of the specific controller interface see the Controller Manual Preparations for running the NetaFlex 3G For NetaFlex 3Gs with an onboard or external controller Run the controller and enter preliminary general settings see the Controller Manual Ensure that the INPUT for protection against low level in the mixing tank is connected to the controller and defined see the Controller Manual Connect all the elements valves pumps filt
15. cal resistant reinforced PVC water hose with an internal diameter of 16 mm that will not contract when there is a vacuum in the system Use properly sealing stainless steel band clamps for the fertilizer acid hose connection type SS 316 16 NETAFLEX 3G INSTALLATION MANUAL ON SITE PREPARATIONS CAUTION vn After completion of the hydraulic infrastructure before the installation of the NetaFlex 3G rinse the hydraulic infrastructure and fertilizer acid lines and tanks by running water through them in order to wash away any residues chips shavings sawdust due to the setup work Electrical preparation Mains connection Jm CAUTION Only qualified electricians are permitted to perform electrical installations FO ATTENTION Make sure the electrical supply capacity is in accordance with the electrical characteristics of the NetaFlex 3G Make sure the short timed higher current consumption when starting up the system pump was taken in consideration for further details see the enclosed Pump Documentation The following components have to be provided in the installation e A readily accessible circuit breaker rated according to the NetaFlex 3G s total rated power for peak demand certified as a branch circuit over current protector see Appendix 2 System Pump List page 35 compliant with the national code and requirements e Grounding connection lt 10 O For the selection of the supply wire size consider see Appe
16. cid filter 9 Water meter LEGEND gt direction of flow 12 JNETAFLEXTM 3G INSTALLATION MANUAL DESCRIPTION Dimensions Table 2 Fig 2 Extrenal dimensions NetaFlex 3G external dimensions W D H 109 148 133 5 cm 43 58 3 52 5 Package dimensions W D H 131 166 159 cm 51 5 65 5 62 5 The height varies by 1 cm 0 5 according to the adjustment of the legs The package height includes the pallet height of 15 cm 6 NOT Weights E The weight of the NetaFlex 3G varies according to the selected system pump Table 3 System pum CM10 3 CM10 4 CM25 2 CM25 3 CR32 3 2 CR32 3 CR45 2 CR45 3 2 CR64 2 1 CR64 2 p Net weight 156 kg 344 lbs 159 kg 351 Ibs 153 kg 337 Ibs 176 kg 388 Ibs 217 kg 478 Ibs 217 kg 237 kg 283 kg 624 Ibs 240 kg 529 Ibs i lI Packed weight 286 kg 631 Ibs 289 kg 283 kg 306 kg 347 kg 414 kg 413 kg 478 lbs 347 kg 765 Ibs 522 lbs 367 kg 809 Ibs I 637 Ibs 624 Ibs 675 lbs 65 Ibs 913 Ibs 911 Ibs 370 kg 816 Ibs Order of magnitude only final weights are issued with the product order Allow 20 cm 8 arround the NetaFlex 3G for inlet outlet and fertilizer pipes connections System pump Packed weight CM10 2 158 kg 348 Ibs 288 kg 635 Ibs CM10 3 161 kg
17. ed voltage 3 x 2204 440V V CM 10 3 acd voltage 3 x 230A 400Y V CM 10 2 iu voltage 3 x 220A 440Y V Nominal current 8 15 4 7 A Consumption 2 35 kW Rated power P2 3 2 kW CM 10 4 Rated voltage 3 x 230A 400Y V Nominal current 8 95 4 3 A Consumption 2 65 kW Rated power P2 4 kW Rated voltage 3 x 220A 440Y V Nominal current 11 8 6 75 A ala Consumption 3 35 kW Nominal current 14 8 7 2 A Rated power P2 4 kW CM 252 ated voltage 3 x 230A 400Y V Consumption 4 15 kW Rated power P2 4 kW Rated voltage 3 x 220A 440Y V Nominal current 14 0 8 2 A SM Tee Consumption 4 15 kW Rated power P2 5 8 kW Rated voltage 3 x 230A 400Y V cM 25 3 Rated voltage 3x 280A 400Y V 3 Nominal current 20 4 11 8 A Nominal current 14 8 7 2 A Consumption 5 95 kW i Consumption 4 15 kW P2 Rated power P2 6 kW CM 25 2 je voltage 3 x 220A 440Y V Nominal current 21 0 10 5 A i Consumption 6 15 kW Rated power P2 5 5 kW 1 CR 32 3 2 BIB voltage 3 x 400A V Nominal current 11 0 A Rated power P2 5 5 kW CR 32 3 Be voltage Z 400A V Consumption 5 65 kW i Nominal current 20 8 A Consumption 7 65 kW Rated power P2 11 kW CR 45 3 2 Rated voltage 3 x 400A V Nominal current 20 8 A Consumption 11 15 kW Rated power P2 7 5 kW CR 45 1 Rated voltage 3 x 440A V Consumption 5 65 kW Nominal current 11 0 A Nominal current 14 2 A Rated power P2 11 kW Rated power P2 11 kW
18. ers sensors etc to the controller see the Controller Manual Manual test of controller outputs Perform the test to make sure that all the elements valves pumps filters sensors etc function properly upon command from the controller Fig 9 Run the test using the controller s TEST menu see the Controller Manual Set the relay status of the dosing channels to MANUAL and make sure that the irrigation program is not defined see the Controller Manual NOTE Make sure the dosing valve selector is in the CLOSED position To check that the dosing channels are working When the OPEN command from the controller is given the LED on the dosing valve is lit Calibration of sensors Calibrate the EC and pH sensors see the EC pH Transducer Manual 23 ATTENTION Unions tend to get loose during transit Before operating the NetaFlex 3G tighten all the unions of the NetaFlex M 3G by hand Filling the NetaFlex 3G with water for the first time CAUTION vn When opening or closing any manual valve always do it gradually to prevent damage to the system by water hammer Gradualy fill the NetaFlex 3G with water until the float valve closes If the float valve does not close the tank may overflow immediatety stop filling the tank and check the float valve for fault Keep the system under static pressure for 10 minutes and visually check for leaks in the filling line Verify that the arm of the float remains horizontal
19. ety instructions C9 n WARNING Always use protective equipment gloves and goggles when handling fertilizers acid and other chemicals JO ATTENTION Table 1 When dosing acid respect the concentration of the acid used For maintenance of drippers Phosphoric Hydrochloric Hydrogen peroxide H2O gt hypochloride o E D S z fe gc SE ecc is by weight at 21 C 70 F The table indicates the resistance of the dosing channel components to acid and is not a recommendation to use the acids mentioned WARNING Exceeding the recommended acid concentrations will damage the dosing channels WARNING Substances such as chemicals for pest disease control might be corrosive and damage the NetaFlex M 3G When using any substance other than fertilizers or acids not exceeding the concentrations in table 1 above always observe the manufacturer s instructions for corrosivity In case of any doubt consult your local Netafim representative 8 NETAFLEX 3G INSTALLATION MANUAL DESCRIPTION Introduction The NetaFlex 3G is a reliable open tank dosing system The NetaFlex 3G ensures very precise and homogeneous nutrient dosing for greenhouse crops The NetaFlex 3G is a modular CE compliant dosing system that easily integrates with multiple Netafim M and third party control and monitoring systems The NetaFlex 3G always injects a uniform quantity of nutrients while performing perfect EC and pH contro
20. fold adaptor Upper lower manifold Ji Venturi Dosing channel Reducer 50mm 1 2 2 PVC threaded plug 1 2 male E Plug 1 4 IL Control tube elbow connector 8 1 4 FT58 iL Pressure gauge 250 GLZ 8 bar 116 PSI 1 4 BSP L 174 17 2 173 174 For spare part ordering call your local Netafim representative having at hand the Serial Number of your NetaFlex 3G Only with this number we can supply the correct part for your specific NetaFlex 3G The Serial Number is inscribed on the side of the switchbox 3530 Tank Outlet Per NetaFlex 3G Serial Number 32 NETAFLEX 3G INSTALLATION MANUAL APPENDIX 1 NetaFlex 3G PARTS LIST Dosing channel Fig 15 See Parts list table 13 page 34 Fertilizer Meter lt a NETAFLEX 3G INSTALLATION MANUAL 33 APPENDIX 1 NetaFlex 3G PARTS LIST Table 13 Dosing channel parts described in figure 15 page 33 Part Description Cd Notes SC Cat NG MI Nipple 3 4 1 2 77300 010470 UPA FSP Hose nozzle end connector for dosing channel 33240 004200 FSP Dosing channel connection between Suitable for dosing channels hose nozzle and Rotameter valve DFM170 501 h 13 GPH 1501 h 40 GPH 33240 004250 10 03 and 400l h 106 GPH FSP Dosing channel connection between Suitable for dosing channels hose nozzle and Rotameter valve DFM185 600l h 158 GPH 33240 004300 Rotameter DFM170 5 50 I hr 1 3 13 GPH 77540 007560
21. he legs so that the NetaFlex M 3G is steady Hydraulic installation g n WARNING When handling fertilizers acid and other chemicals always use protective equipment gloves and goggles NetaFlex inlet outlet connection Connect the appropriate pipes to the inlet and the outlet of the NetaFlex 3G see Location of inlet outlet and fertilizer acid line connectors page 15 Table 10 Two types of connectors are supplied Diameter mm inch PVC adaptor union BSP or NPT nipple System pump glue connector installed male thread connector supplied EE 63 mm ICM25 CT 32 5 75mm ICRA5 45 T O R 18 NETAFLEX 3G INSTALLATION MANUAL INSTALLATION Stock tank connection Connect the fertilizer lines to the NetaFlex 3G see Location of inlet outlet and fertilizer acid line connectors page 15 Table 11 Three types of connection are available Fittings interchangeable PVC hose nozzle insert connector installed PVC nipple male thread connector supplied PVC half union female thread connector supplied Prior to flexi tube connection thread a stainless steel band clamp on each flexi tube hose Heat the tip of each Flexi tube hose in boiling water to make it flexible for insertion Connect flexi tube hose from fertilizer lines to the hose nozzle insert connectors of dosing channels ensuring 1 2 meter 1 7 feet of transparent chemical resistant reinfo
22. icity Ensure that suitable electrical power supply is available in the vicinity of the installation for the NetaFlex 3G electrical connection see Electrical Installation p 20 Ensure an electrical socket available in the NetaFlex 3G vicinity for installation and for service purposes Safety instructions All safety regulations must be applied Ensure that the installation is carried out in a manner that prevents leaks from the NetaFlex M 3G 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 IU WARNING In agricultural environment always wear protective footwear WARNING Measures must be taken to prevent fertilizer infiltration of the water source to avoid water pollution CAUTION vn When opening or closing any manual valve always do it gradually to prevent damage to the system by water hammer NOTE The maximum sound level produced by the equipment does not exceed 70dB NETAFLEX 3G INSTALLATION MANUAL 7 INTRODUCTION When using acid chemicals FN ACID HAZARD When using acid always observe the acid manufacturer s saf
23. id solutions in the stock tanks have been thoroughly agitated before starting the simulation 24 NETAFLEX 3G INSTALLATION MANUAL CALIBRATION Note the required dosing ratio of each fertilizer solution and the dosing ratio of the acid solution if used Fill a bucket with 10 liters 2 US gallons of the client s supply water without fertilizer or acid Measure the EC and the pH levels of the water in the bucket using calibrated portable sensors EXAMPLE Supply water without fertilizer or acid Using a measuring tube or a syringe take a dose from each fertilizer solution and from the acid solution if used according to the proportions determined by the dosing ratio see example below and mix thoroughly with the water in the bucket EXAMPLE Metric units 7 MP 2 S For a fertilizers dosing ratio of 10 l m each and an acid dosing ratio of 2 l m the quantities for 10 liters of water in the Bucket simulation test will be 100 cc of each fertilizer solution and 20 cc of the acid solution 10 liters 2 US gal US units For a fertilizers dosing ratio of 3 0 US gal THG each and an acid dosing ratio of 1 1 US gal THG the quantities for 2 US gallons of water in the Bucket simulation test will be 0 76 oz of each fertilizer solution and 0 28 oz of the acid solution Fig 11 DEFINITIONS 1 US gal 2 128 oz 30 X 2 1000 11X2 1000 0 006 US gal 0 768 oz 0 0022 US gal 0 28 oz Mea
24. ided the installation has been reported to Netafim M within 30 days of installation If the installation was not reported or was reported later than 30 days from the date of installation Netafim will warrant the NetaFlex 3G for a period of 18 months from the date of production according to its serial number If a defect is discovered during the applicable warranty period Netafim will repair or replace at its discretion the product or the defective part The above does not apply to EC and pH sensors since they are wearable Netafim will warrant these items to be free of defects in material and workmanship for 3 months from the date of installation provided the installation has been reported to Netafim within 30 days or 6 months from date of production if installation was not reported or was reported later than 30 days from the date of installation CAUTION vn When not installed the pH sensor must be immersed in KCL solution supplied with the sensor or in calibration buffer 4 at temperature 18 25 C 64 77 F protected from freezing and not be exposed to pressure greater than 6 bars 87 PSI Damage due to these causes is not covered by warranty This warranty does not extend to repairs adjustments or replacements of a NetaFlex M 3G or part that results from misuse negligence alteration force majeure lightning power surge improper installation or improper maintenance If a defect arises in your Netafim product
25. l The NetaFlex 3G can accommodate a wide variety of dosing channels for fertilizer and concentrated diluted acid Up to 6 dosing channels of various types from 50 I hr 13 GPH each up to 600 I hr 158 GPH each in many mixed configurations The NetaFlex 3G accommodates a wide variety of system pumps peripherals and accessories to meet a vast range of applications and infrastructure constraints Highlights e Wide range of soil substrate applications e Built around a standard platform e Minimal investment requirement e Efficient water fertilizer and energy consumption e Very large range of irrigation water capacities e Quantitative or proportional Nutrigation capabilities e Precise EC and pH control e Almost completely maintenance free Venturi operations no moving parts e Highly accurate dosing channels equipped with quick action dosing valves e Fast and efficient Nutrigation recipe adjustments e Easy integration into existing irrigation systems Netafim s NMC and third party controllers e Multilingual system e Wide range of integrated accessories and peripherals e High quality components and PVC e Aluminum corrosion resistant frame with adjustable legs e Made by Netafim Advantages e Easy to install and maintain system e Highly profitable price performance ratio e Requires minimal investment with rapid ROI e Productive Employing precise EC and pH control assists in delivering a high quality product with
26. l installation overview External dimensions Hydraulic infrastructure required proportions Location of connectors The ShockWatch label Fertilizer acid lines connection Rotation of the hose connectors The dual dosing channel The dosing valve selector Adjustment of the Rotameter cursors Simulation test with a 10 liter 2 US gal bucket of water EC and pH range Parts 100 L Horizontal pump Parts 200 L Vertical pump Parts Dosing channel Parts Venturis Schematic diagram Infrastructure schematic diagram The dual dosing channel NETAFLEX 3G INSTALLATION MANUAL 5 USE OF SVMBOLS The svmbols used in this manual refer to the following WARNING The following text contains instructions aimed at preventing bodilv injurv or direct damage to the crops the NetaFlex 3G and or the infrastructure CAUTION WE following text contains instructions aimed at preventing unwanted svstem operation installation or conditions that if not followed might void the warrantv yo 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 TN ACID HAZARD The following text contains instructions aimed at preventing bodily injury or direct damage to the crops the prod
27. lectric output Enables continuous reading of fertilizer dosing Useful in applications where the costumer wants a broader indication on fertilizer flow on top of the EC and pH readings Stock selection Enables the dosing of multiple fertilizers through a single dosing channel in cases where simultaneous dosing is not required Available in a wide variety of configurations from a single channel with 2 fertilizers to as many channels and fertilizers as required For further information on the NetaFlex 3G add ons consult your local Netafim M representative Diagram 1 Schematic diagram Se EA TE Ar AMAR l b mx g PR LEGEND scope of delivery direction of flow Q System pump O EC sensors 2 Filling pump B Tank Q pH sensors 2 Filling line filter Dosing channel Venturi Q Float valve D Pressure reducing valve 6 Control panel including 6 Pressure gauge Fertilizer acid stock tank Controller EC pH tranceducer 9 Upper manifold filter 9 Manual valve fertilizer electric switchboard D Low level switch Fertilizer acid filter D Non return valve B Water meter NETAFLEX 3G INSTALLATION MANUAL 11 DESCRIPTION Fig 1 Typical installation overview The drawing below represents a typical NetaFlex 3G infrastructure NetaFlex 3G Q Filling pump B Filling line filter D Pressure reducing valve B Fertilizer acid stock tank 9 Manual valve fertilizer D Fertilizer a
28. ndix 2 System Pump List page 35 e The NetaFlex 3G s total rated power e Whether the electricity supply is single phase or three phase Table 9 Mains wire size for three phase system 5 wires GND N L1 L2 L3 Power source required kWatt 3 X 200 250 VAC 3 X 400 480 VAC gt 2 5 mm x 13 awg gt 6 mm s 9 awg gt 4 mm lt 11 awg gt 10 mm lt 7 awg Ecce 10 12 gt 16 mm lt 5 awg gt 10 mm lt 7 awg 12 16 gt 25 mm lt 3 awg Using a cable not longer than 25 meter 82 feet between the power supply and the switchboard of the NetaFlex 3G NETAFLEX 3G INSTALLATION MANUAL 17 INSTALLATION Unpacking and placement Check the ShockWatch label attached to the packaging and ensure the indicator is white WARNING MONITORED SHIPMENT If the indicator is red act according to the instruction IF SHOCKWATCH shachwatc com 180052798 on the ShockWatch label INDIA AH WARN l NG Place the NetaFlex 3G package close to the irrigation LK l Make notation on delivery receipt and war wur system using forklift R EUR um damage is discovered leave item in original container and packaging and request Gentiv open the packaging 15 days of delivery date int13 dayah Remove the 4 screws and bolts connecting the NetaFlex 3G to the wooden pallet SHOCKWAICH e ee Remove plastic cover from controller if existing Fig 5 Place the NetaFlex 3G in its position Adjust t
29. ontroller NMC Pro screen 7 6 26 NETAFLEX 3G INSTALLATION MANUAL CALIBRATION If the EC and pH target values cannot be attained and the dosing valves are opened more than 85 measures should be taken to increase the dosing ratio if feasible slightly increase the concentration of the fertilizer solution and or reduce the water flow rate to the field during Irrigation If not consult the agronomist consultant In a field where the flow rate changes significantly from one irrigation shift to the next try to be at a minimum of 50 dosing valve opening for the low flow rate shift and a maximum of 80 for the high flow rate shift When the calibration process is completed return to the EC and pH control screen in the controller define the deviation in EC and pH values for the channels and switch the EC and pH control to ON NMC Pro screen 7 7 7 6 In the EC and pH alarm definitions define the EC and pH deviation from the target values that if attained will trigger the alarm and set the EC and pH alarm to the ON position activated NMC Pro screen 3 5 3 6 NOTE EC and pH values must not exceed a 30 deviation from the target values Ja ATTENTION Once a month read the measured flow rates of the dosing channels and compare them with the flow rates defined in the controller in order to check whether changes have occurred NMC Pro screen 7 6 After completing the calibration process write down the data as refe
30. outstanding yields single or dual EC and pH control sets are available e Uniform Delivers a consistent quantity or ratio of nutrients in a homogenous solution thanks to an open mixing tank design e Flexible Works with a wide range of dosing channel flow rates up to 6 units of 50 600 I hr 13 158 GPH Each dosing channel is fitted with a multipurpose dosing valve for the dosing of fertilizer or acid at any dosing rate up to 600 I hr 158 GPH Compatible with 50 60 Hz electricity frequency e Scalable System flow rates from 3 m h 13 GPM to 64 m3 h 282 GPM e Focused Made for soil soilless greenhouse applications NETAFLEX 3G INSTALLATION MANUAL 9 DESCRIPTION Specifications Output flow rate and pressure The NetaFlex 3G ensures a satisfactory mixture in a vast range of system performances Flow rate from 3 m3 h 13 GPM to 64 m3 h 282 GPM at a wide range of output pressure according to the selected system pump A single NetaFlex 3G will accommodate from a 0 1 Ha 0 25 Acres to a 10 Ha 25 Acres nursery For output pressure lower than 3 0 bar 44 PSI consult your local Netafim representative Fertilizer dosing capacity The NetaFlex 3G accommodates up to 6 dosing channels of various types in many mixed configuration e 50 I hr 13 GPH e 150 I hr 40 GPH e 400 I hr 105 GPH e 600 I hr 158 GPH For applications requiring more than 6 dosing channels consult your local Netafim representative
31. rced PVC water hose with an internal diameter of 16 mm that will not contract when there is a vacuum in the system Attach the stainless steel band clamp on each flexi tube connection and secure tightly Flexi tube specification e 16 mm reinforced EVA tubing e Material EVA ethylene vinyl acetate tube compound specially formulated to meet USDA requirements e Polyester cord reinforcement with color tracer e Pressure 18 to 20 Bar 250 to 300 PSI e Recommended temperature range 23 C to 65 C 10 F to 150 F Fig 6 TIP 9 You can rotate the hose connectors of the dosing channels to face the desired direction according to the location of the stock tanks Loosen the Rotameter s lower connector rotate the hose connector to the desired direction B and fasten the Rotameter s lower connector Q Fig 7 NETAFLEX 3G INSTALLATION MANUAL 19 INSTALLATION Dual dosing channel If the NetaFlex has more than 4 dosing channels up to 6 the dual dosing channel option is utilized e Up to 2 dual dosing channels are installed on the NetaFlex 3G at the farthest manifold positions 1 and 4 e The dual dosing channel option is applicable with 600 I hr 158 GPH or 50 I hr 13 GPH Venturis Diagram 3 Dual dosing channels schematic diagram E mp 7 LEGEND scope of the dual dosing channel T de X yy y amp T gt direction of flow Jm CAUTION There are fertilizer com
32. rence for calibration of the NetaFlex 3G in the future NETAFLEX 3G INSTALLATION MANUAL 27 After completing the calibration process the NetaFlex 3G is ready for commissioning Familiarize the client with the NetaFlex 3G the user manual and the accompanying documents and emphasize the following points e The importance of following all the safety instructions see User Manual pages 6 7 e The warranty and its restrictions see User Manual page 21 e Calibration accompany the client through this chapter and emphasize the importance of thorough knowledge of the processes in it for the current operation of the NetaFlex 3G see User Manual page 22 e Proper dissolving of fertilizers for optimal utilization of the dosing channels capacity see User Manual page 22 e The importance of regular maintenance and its impact on the warranty see User Manual page 14 e The importance of periodically comparing the hydraulic data with the initial settings in the controller see User Manual page 15 e Troobleshooting accompany the client through this chapter see User Manual pages 16 20 e Instruct the client to regularly keep track of the NetaFlex 3G Hydraulic Conditions for future reference 28 NETAFLEX 3G INSTALLATION MANUAL WARRANTY Netafim warrants all the components of the NetaFlex 3G to be free of defects in material and workmanship for 1 one year from the date of installation prov
33. sure the EC and the pH levels of the mixture in the bucket using calibrated portable sensors Compare the measured EC and pH values to the target values set by the agronomist consultant EXAMPLE After adding the fertilizers and acid Target values Deviation from target value F WN Fig 12 30 Target value 30 NETAFLEX 3G INSTALLATION MANUAL 25 CALIBRATION With the controller set to operate according to EC pH values if the EC and pH values measured in the bucket are within a range of 30 deviation from the target values the system will be able to correct them automatically If the values are out of the 23096 range check the data and consult the agronomist consultant 3 Calibration of the NetaFlex 3G while irrigating N WARNING Extreme EC or pH values mav damage the crop Perform the following procedure only after completing stage 2 above Simulation test with a 10 liter or 2 US gallon bucket of water with satisfactory results NOTE The following steps explain the operations to be performed regardless of the type of controller used For the operation of your controller s interface consult the Controller Manual However since the NMC Pro controller is widely used its interface screens for the execution of each step are noted NOTE Before the calibration confirm that the EC and the pH sensors of the NetaFlex 3G have been calibrated according to the instructions in the EC pH Installation Manual
34. taFlex 3G operation the following requirements must be met e Source water should enter the NetaFlex 3G at a flow rate equal to the maximum flow rate required for the field If the flow rate at the inlet of the NetaFlex 3G is insufficient the low level switch will be activated and the NetaFlex 3G operation will be stopped 14 NETAFLEX 3G INSTALLATION MANUAL ON SITE PREPARATIONS e The water entering the NetaFlex 3G should be within a pressure range of 2 to 4 5 bar 29 PSI to 65 PSI NOTE To ensure flow rate stability the consumption of the individual irrigation shifts should be as equal as possible Each changeover between shifts with different consumption will result in consumption fluctuation that will affect the EC and pH stability The consumption of the smallest shift should not be less than 7596 of the consumption of the largest shift Pump house Filter house Fertilizer house requirements Jm CAUTION The NetaFlex 3G should be placed in a roofed building not be exposed to direct sunlight kept at an ambient temperature between 10 C and 40 C 50 F and 104 F kept at a maximum relative air humidity of 8596 be properly ventilated be protected from dust be protected from splashes or direct spraying with water or chemicals NOTE In order to prevent penetration of fertilizer or acid to the soil it is recomended that the floor of the pump house have a slope of minimum 196 towards a g
35. uct and or the infrastructure in the presence of acid AN ELECTRICAL HAZARD The following text contains instructions aimed at preventing bodily injury or direct damage to the NetaFlex 3G and or the infrastructure in the presence of electricity SAFETY FOOTWEAR The following text contains instructions aimed at preventing foot injury g 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 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 TIP 9 The following text provides clarification tips or useful information 6 NETAFLEX 3G INSTALLATION MANUAL INTRODUCTION CAUTION vn Read the Safety instructions chapter before beginning installation of the NetaFlex 3G dosing unit General instructions Installation must be performed by authorized technicians only Refer to your supervisor if problems occur during installation procedure nstallation should be performed on a hard leveled floor or on a flat hard leveled plate Do not apply force or pressure on components during the installation procedure Verify that field components work properly Make sure fertilizers and acid are on site at time of installation Electr
36. utter at its lower edge and an underground tank at the lower end of the gutter enabling drainage of any spill or excess Location of inlet outlet and fertilizer acid line connectors The location of the inlet and the outlet connectors vary according to the selected system pump Outlet E f lm i lail H erti lizer acid lines connect A Fig 4 PEN eee A jat gt C Table 5 11 4 cm 4 5 15 8 cm 6 2 97 5 cm 38 4 18 3 cm 7 2 The height varies by 1 cm 0 5 according to the adjustment of the legs NETAFLEX 3G INSTALLATION MANUAL 15 ON SITE PREPARATIONS The water distribution system For the setup of the water distribution system the following components should be installed Table 6 Components of the water distribution system Filling pump Suitable for flow rate satisfying the maximum field requirement Ensure stable pressure B Filling line filter 130 um 2 120 mesh D Pressure reducing valve Should be installed on the filling line downstream from the filling line filter PRV and be able to supply suitable pressure as specified for the NetaFlex 3G ilizer B Fertilizer acid stock tank Between 1 and 6 fertilizer acid solution stock tanks 9 Manual valve fertilizer A manual ball valve on each fertilizer acid line at the stock tank outlet
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