Fertilizer Applicator Certification Training

Module 9: Sprayer Calibration

Virginia Cooperative Extension Virginia Department of Agriculture and Consumer Services Virginia Department of Conservation and Recreation

After module completion, one will

1) know the importance of calibration. 2) understand the strengths and limitations of applying fertilizer with a sprayer. 3) understand the basic steps and calculations in calibrating a sprayer. 4) understand the basic calculations and importance in measuring and knowing the area to be treated when applying product with a sprayer.

Be in the KNOW
Know your product Know what is in the product Know your equipment Know your area Know your speed and pressure

What is calibration?
By definition, calibration means to alter or regulate so as to achieve accuracy or conform to a standard We calibrate spreaders and sprayers to ensure that we are accurately delivering a specific amount of nutrient to a known area that conforms to standard nutrient management recommendations.

What is the importance of calibration?

A properly calibrated machine ensures accurate delivery of nutrients, thereby:
Promoting turf and landscape plant health Protecting the environment Improving the efficiency (in time, labor, and cost) of the application.

Once calibrated, always calibrated?

No! Expect sprayer calibrations to change due to:
Equipment operation and/or wear (variances in pressure, pumps, nozzles, tips, etc.) Changes in operator or equipment speed Possible changes in product formulation

Record calibration settings for specific machines and products Periodically recalibrate to ensure accurate delivery

Sprayer Calibration PPE for spray applications

Fertilizer delivery by spray solution typically requires some basic Personal Protective Equipment (PPE) per label or Material Safety Data Sheet (MSDS) requirements (specific gloves, long pants or shirt sleeves, specific boots, etc.).

If a pesticide is added to the fertilizer solution to be sprayed, be sure the PPE selected meets the label requirements for the pesticide as well.

Sprayer operation
Water is almost always the carrier for either solutions (product completely dissolved in water) or suspensions (as name suggests, the product is suspended in water). Suspensions require thorough mixing and/or agitation in order to keep the product properly suspended in the liquid and ensure accurate delivery. Proper calibration and product delivery is dependent on a consistent speed of delivery and spray pressure in the application.

Equipment selection
It is beyond the scope of this training to detail the selection of appropriate pumps, nozzles, tips etc. but the calibration strategies for delivery of specific amounts of solution with different spraying systems are essentially the same.

This module will detail the basic calibration steps for three spray delivery methods
Single nozzle spray gun (typical to professional lawn care operators) nozzles usually offer flow rates of 1.5 to 4 gallons per minute and tanks hold 50 or more gallons of spray solution

This module will detail the calibration steps for three spray delivery methods
Backpack sprayer calibration (typical to most homeowners; 3 to 4 gallon sprayers)

This module will detail the calibration steps for three spray delivery methods
Multi-nozzle boom sprayer (typically to golf superintendents and/or sports turf managers); tanks hold 50 gallons or more of solution.

Advantages of spray applications

Advantages of sprayer delivery:
Rapid and uniform product delivery by using water as a carrier Ability to specifically direct where product is being applied (i.e. keep materials off of non-target hardscapes and vegetation) Ability to mix with a variety of other liquid chemical formulations

Disadvantages of spray applications

Disadvantages of sprayer delivery: Sprayers have many parts to select and maintain to ensure accurate performance (pumps, pressure valves, nozzles, tips) Wind can affect delivery Lawn areas must be free of debris before spraying (in particular leaves) Consistent applicator speed and pump pressure required for proper delivery Foliar burn potential?

Tools required for calibrating a sprayer

Flags or marking paint A tape measure to measure length of course distance and width of sprayer pattern or perhaps nozzle spacing or boom height Stop watch Graduated container for collecting Calculator

Other considerations in fertilizer delivery by spray systems

Spray pressures can obviously be adjusted but are typically in the range of 15-45 psi for most lowpressure lawn and landscape applications.

Other considerations in fertilizer delivery by spray systems

The output of a sprayer has a direct inverse relationship to sprayer speed. For instance, doubling the speed reduces output by ; reducing speed by doubles the output. Changing pressure is not quite a direct inverse relationship as for speed. For instance, to double the flow rate, pressure must be increased 4x. But in general, as pressure increases, the output also increases, along with a decrease in droplet size and increased wear on the sprayer orifices (tips, nozzles etc.). Be sure to select appropriate nozzles and tips for the pressure ranges desired for the application.

Fertilizer sources for spray applications

Liquid fertilizer formulations usually have inherent advantages in mixing and delivery as most form spray solutions very quickly. However, care must be taken when mixing with other fertilizer and/or chemical formulations regarding both physical and chemical properties. Consult labels for both fertilizer and pesticides before mixing and conduct a jar test to ensure chemical compatibility

Fertilizer sources for spray applications

Fertilizer Analysis Salt Index (>2.5 Water = high; 2.5 to Solubility 1=mod; <1 = low) g/L (lb/gal)

Ammonium nitrate Urea Ammonium Sulfate Potassium nitrate

34-0-0 45-0-0 21-0-0 13-0-44

3.2 1.7 3.3 5.3

1810 (15) 780 (6.5) 710 (5.9) 130 (1.1)

After A.J.Turgeon, Turfgrass Management

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Calibrating a spray gun

Choose an appropriate spray pressure suitable for the nozzle and tip on the spray gun Determine a suitable spray swath width with the gun (6 to 10 feet widths waving the wand from side to side is typical), planning on making a slight overlap in spray swath as product is applied. Also decide on a calibration length, keeping in mind that length by width measurements that total 1000 sq ft make calculations easier. Establish a consistent and repeatable walking speed and apply water over a known length by width spray course over a recorded time interval.

A target speed is often 3 mph (or 4.4 feet per second), but the most important thing is for the speed of delivery to be constant.

Calibrating a spray gun

Record the time required to cover the calibration course. Collect discharge in a measuring cup/bucket for the recorded time period to determine spray volume per unit area. (Note: LCOs typically strive for the delivery of 1.5 to 2 gallons of spray solution per 1000 sq ft with spray gun applications). Repeat the process until target delivery rate is achieved.

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Example Sprayer Calibration Calculations Spray Gun

If the sprayer width from a spray gun application is 8 feet, how long (feet) must the calibration distance be to cover the desired 1000 sq ft in area for the calibration run? 1000 ft2 area desired 8 ft spray swath width = 125 ft in calibration course length needed

Example Sprayer Calibration Calculations Spray Gun

If the goal is to establish a 3 mph walking speed (4.4 ft/second = 3 mph rate), how long will it take to cover the 125 foot course length? 125 ft length 4.4 ft/second = approximately 28 seconds. NOTE: If the applicator calibrates their pace to 28 seconds to cover the 125 ft course length with an 8 ft sprayer swath, then whatever volume of spray they collect over a 28 second period will be the spray volume per 1000 sq ft of area. If the target is 2 gallons per 1000 sq ft, then the applicator will collect 2 gallons of water (or 2 gallons * 128 oz/gallon = 256 ounces of water) in the calibration run. If the targeted volume of spray solution delivery is not achieved, the applicator can alter their speed, the pump pressure, and/or the nozzles/tips for the delivery.

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Another way to calibrate delivery rate of a spray gun

Check flow rate by collecting material from the gun for 1 minute. Measure the time required to spray 1,000 square feet. The time required to spray 1,000 square feet x flow rate = application rate in gallons per 1,000 feet. Adjust application rates by changing pressure or application speed. Example:
1.5 gallons collected from gun for 1 minute 2 minutes required to spray 1,000 square feet 1.5 gallons x 2 minutes = 3.0 gallons per 1,000 square feet application rate.

As long as application speed and sprayer pressure remain consistent, the calibration holds.

Spray Gun Calibration Calculations

The situation. The spray gun is calibrated to deliver 2 gallons of solution per 1000 sq ft. The spraying system is connected to a 100 gallon tank on a truck. If the goal is deliver lb of N per 1000 sq ft, how much urea will be dissolved in a full tank (100 gallons) of solution for spray applications? 2 gallons : :100 gallons 2(x) = 100(1000) 2x = 100,000) x=50,000 sq ft 1000 sq ft x sq ft 0.5 lb N : : x lb N 0.5(50,000) = 1000(x) 25,000= 1000(x) 1000 sq ft 50,000 sq ft 25,000 1000 = 25 lbs N per 1000 sq ft 25 lbs N 0.45 = 55.6 lbs 45-0-0 to be placed in the tank Fill the tank approximately 1/3 rd with water, add the 55.6 lbs of urea, agitate (if necessary) and fill the tank to the 100 gallon mark. The sprayer is now calibrated to deliver lb N/1000 sq ft if speed, pressure, etc. remain the same.

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Backpack sprayer calibration

As before, establish a course length, determine swath width (spraying on a road or sidewalk works great) and record the time to cover a known area of distance (course length by spray swath width). Course lengths of at least 50 feet are desired.

Backpack sprayer calibration

If available, use a pressure regulator to ensure constant pressure during the application. While maintaining constant pressure, capture the discharge for the same time duration it took to cover the calibration area.

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Backpack Sprayer Calibration Calculations

The situation. It took 18 seconds to cover a calibration run with a 3 gallon backpack sprayer over a calibration course using a 3 ft sprayer width and a 100 ft course length. When collecting the spray for the 18 second time period, 50 ounces were collected. What is the volume that the sprayer is calibrated to deliver? How much area (square feet) can a full sprayer cover? If the goal is to deliver N at 0.25 lb N/1000 sq feet with ammonium sulfate (20-0-0), how many lbs of 20-0-0 are placed into a full sprayer tank? 50 oz : : x fl oz 1000(50) = (300)x 50,000 = 300x x=166.7 fl oz 300 sq ft 1000 sq ft 166.7 fl oz 128 fl oz per gallon = 1.3 gal per 1000 sq ft A 3 gallon sprayer calibrated to deliver 1.3 gal per 1000 sq ft can cover: 1.3 gal : : 3 gal 1.3(x) = 1000(3) 1.3(x) = 3000 2,308 sq ft 1000 sq ft x sq ft

Backpack Sprayer Calibration Calculations

The situation. It took 18 seconds to cover a calibration run with a 3 gallon backpack sprayer over a calibration course using a 3 ft sprayer width and a 100 ft course length. When collecting the spray for the 18 second time period, 50 ounces were collected. What is the volume that the sprayer is calibrated to deliver? How much area (square feet) can a full sprayer cover? If the goal is to deliver N at 0.25 lb N/1000 sq feet with ammonium sulfate (20-0-0), how many lbs of 20-0-0 are placed into a full sprayer tank? Since a 3 gallon tank can cover approximately 2,300 sq ft, how much 20-0-0 is required to deliver the desired N level of 0.25 lb N/1000 sq ft? 0.25 lb N : : x lb N 2300(0.25) = (1000)x 575 =1000(x) 1000 sq ft 2300 sq ft 0.58 lb N; 0.58 0.20 = 2.9 lbs 20-0-0 Place approximately 1 gallon of water in the sprayer, add the 2.9 lbs of 20-0-0, stir until fertilizer is dissolved, and fill sprayer to 3 gallons.

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Backpack Sprayer Calibration Calculations

The situation. Use previous calibration information for the backpack sprayer that was determined that a 3 gallon tank can cover 2,300 sq ft. What if one only has 1500 feet of lawn to cover it would not make sense to make up a full tank of fertilizer solution. So, keeping pressure, speed etc. constant, how much fertilizer and how much spray volume will be placed into the sprayer in order to treat 1500 sq ft of area at a 0.25 lb N/1000 sq ft level using 20-0-0 fertilizer? 0.25 lb N : : x lb N 1500(0.25) = (1000)x 375 =1000(x) 0.38 lb N 1000 sq ft 1500 sq ft 0.38 lb N 0.20 = 1.9 lbs 20-0-0 to be placed in the sprayer tank 3 gal : : x gal 1500(3) = (2300)x 4500 =2300(x) approx. 2 gal 2300 sq ft 1500 sq ft Place approximately 1 gallon of water in the sprayer, add the 1.9 lbs of 20-0-0, stir until fertilizer is dissolved, and fill sprayer to 2 gallons and the sprayer is calibrated to treat 1500 sq ft.

Calibrating a multi-nozzle boom sprayer

Additional factors to consider for calibration in this spray delivery method are appropriate nozzle spacing on the boom to gain proper overlap of spray pattern AND an appropriate boom height off the ground. This information should be provided in the operators manual for the spray system or the users catalog for the spray nozzles and tips. Determine the spray pattern width by multiplying the distance between nozzles by the number of nozzles on the boom, determine a course length and calculate area as previously described.

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Calibrating a multi-nozzle boom sprayer

Checking the spray pattern of the water on a hardscape (such as a gravel or concrete driveway) is a great way to ensure appropriate spray overlap (suitable to the tip selected) and boom height. As before, a target speed is often 3 mph (or 4.4 feet per second), but the most important thing is for the speed of delivery to remain constant.

Boom sprayers are most often used on large open areas free of trees and/or other immovable objects.

The Ounce Method of boom sprayer calibration

Since a gallon equals 128 ounces, if a sprayer is calibrated on an area measuring 1/128th of an acre (1 A = 43,560 sq ft 128 = 340 sq ft), then the ounces of spray solution captured from one nozzle during the known time of the calibration run to cover the 340 sq feet equates to the sprayers delivery on a gallons per acre basis.
Course lengths required to calibrate 1/128th of an acre (340 square feet).
Boom nozzle spacing (in.) 12 16 20 24 28 32 36 40 Course length 340 255 204 170 146 127 113 102

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The Ounce Method of boom sprayer calibration

Measure off the required course length according to the uniform nozzle spacing on the boom (use table provided on previous slide). Record the time it takes to travel the entire course length.

The Ounce Method of boom sprayer calibration

The spray discharge from one nozzle captured over the time required to calibrate the appropriate course length based on the nozzle spacing will equal the sprayers gallons per acre (GPA) delivery as long as pressure and speed remain constant. When possible, collect the discharge from multiple nozzles and determine an average nozzle output in order to compare numbers and to ensure all nozzles and tips are performing similarly AND properly.

As a rule of thumb, if the discharge from any nozzle/tip exceeds 5% of the average nozzle output, that nozzle/tip should be inspected to see if there are any blockages, signs of obvious wear etc., and if so, the nozzle or tip should be repaired or replaced.

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Multi-nozzle Boom Sprayer Calibration Calculations

The situation. Your goal is to apply N at 0.5 lb N/1000 sq ft using a 20-0-0 water soluble source. The sprayer is equipped with a 75 gallon tank. The nozzle spacing is 20 inches and using the information presented in the table on slide 33, the course length to provide 1/128th of an acre (340 sq ft) is 204 feet. This length is measured. Assuming that the pressure is constant, if the goal is to drive 3 mph (4.4 feet per second), approximately how long will it take to drive the 204 feet course length for the calibration? After determining the time to cover the length, capturing the nozzle discharge for that amount of time results in a collection of 30 ounces (i.e. a 30 GPA discharge). How many sq feet can a full sprayer tank cover? 4.4 ft 1 sec : : 204 ft x sec x(4.4) = (204)1 approx. 46 seconds

30 gal : : 75 gal x(30) = 75(43,560) 30x = 3,267,000; x=108,900 ft 2 43,560 ft2 x ft2

Multi-nozzle Boom Sprayer Calibration Calculations

The situation. Your goal is to apply N at 0.5 lb N/1000 sq ft using a 20-0-0 water soluble source. The sprayer is equipped with a 75 gallon tank. The nozzle spacing is 20 inches and using the information presented in the table on slide 33, the course length to provide 1/128th of an acre (340 sq ft) is 204 feet. This length is measured. Assuming that the pressure is constant, if the goal is to drive 3 mph (4.4 feet per second), approximately how long will it take to drive the 204 feet course length for the calibration? After determining the time to cover the length, capturing the nozzle discharge for that amount of time results in a collection of 30 ounces (i.e. a 30 GPA discharge). How many sq feet can a full sprayer tank cover? How many pounds of 20-0-0 will be added to the full tank (75 gallons) if your goal is to apply 0.5 lb N/1000 sq ft? 0.5 lb N 0.20 = 2.5 lbs 20-0-0 per 1000 sq ft 2.5 lb fert : : x lb fert 108,900(2.5) = x(1000)272,250=1000x 272.25 lbs 1000 ft2 108,900 ft2 One would fill the tank approximately 1/3 to 1/2 full of water, add the fertilizer, stir/agitate, and fill the tank to the final 75 gallon volume.

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Multi-nozzle Boom Sprayer Calibration Calculations

The situation. Using all of our previous calibration information from the previous two slides (same sprayer, nozzle spacing, speed, pressure etc.), what if one only needed to treat acre (21,780 sq feet) of area at the desired level of 0.5 lb N/1000 sq using the 20-0-0 source. How many pounds of 20-0-0 will be added to the tank if your goal is to apply 0.5 lb N/1000 sq ft? What would be the final volume in the spray tank in this situation? How much 20-0-0 will be added to deliver 0.5 lb N/1000 sq ft? 75 gal : : x gal 21,780(75) = x(108,900)1,633,500=108,900x 15 gal 108,900 ft2 21,780 ft2 We previously determined that we need 2.5 lbs 20-0-0 per 1000 sq ft to deliver 0.5 lb N per 1000 sq ft. x lb fert : : 2.5 lb fert 1000(x) = 2.5(21,780)1000x =54,45054.5 lbs fert 21,780 ft2 1000 ft2

Multi-nozzle Boom Sprayer Calibration Calculations

The situation. Using all of our previous calibration information from the previous two slides (same sprayer, nozzle spacing, speed, pressure etc.), what if a liquid fertilizer source N source (a 20-2-3 product weighing 11 lbs per gallon) is desired to be used to deliver the 0.5 lb N/1000 sq ft level? Consider a full tank application how many gallons of 20-2-3 are required to deliver 0.5 lb N/1000 sq ft? Each gallon of fertilizer contains 0.2 x 11 lbs = 2.2 lbs N. 1 gal : : x gal 1(0.5) = x(2.2)0.23 gal fert are required per 1000 sq ft 2.2 lbs N 0.5lb N We previously determined that a full sprayer tank will cover 108,900 sq ft. So, 0.23 gal : : x gal 108,900(0.23) = x(1000)25,047=1000x25 gallons 1,000 ft2 108,900 ft2

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Additional strategies for improving fertilizer delivery by spray systems

There are several tools that can be used to either direct spray or to minimize spray drift. Spray shields and sprayer skirts are two possible methods in targeting spray delivery.

Additional strategies for improving fertilizer delivery by spray systems

A tracking dye to indicate area covered by the spray application is pictured here and these dyes are used with all types of sprayers. Foam markers are often used with boom sprayers.

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Know the area being treated

It makes agronomic, environmental, and economic sense to know

L*W

the area being treated. Divide lawns and landscapes into simple

1 2 B*H

(AB)*W

geometric figures in order

r2

r2

to calculate square footage. GIS technology and smart phone apps?

Additional resources of interest

Grisso, R., P. Hipkins, S. D. Askew, L. Hipkins, and D. McCall. 2009. Nozzles: Selection and Sizing. Virginia Cooperative Extension Publication 442-032. http://pubs.ext.vt.edu/442/442-032/442-032.html.

Grisso, R., M. Weaver, K. Bradley, S. Hagood, and H. Wilson. 2009. Fine Tuning a Sprayer with Ounce Calibration Method. Virginia Cooperative Extension Publication 442-453. http://pubs. ext.vt.edu/442/442-453/442-453.html.

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Review of basic considerations with sprayer applications

Using water as a carrier can greatly increase the uniformity and distribution of fertilizers if a sprayer is properly calibrated. Application speed and pressure must remain constant for all sprayer calibrations and applications. Excessive wind and presence of lawn debris can limit the use of foliar applications, but spray gun and backpack sprayer applications offer precise delivery, whereas multi-nozzle boom sprayers mounted to an engine-driven vehicle can cover large areas of open area reasonably fast.

Next steps
Additional training exercises regarding basic calculations for sprayer calibration are provided on the Scholar site. To complete this module you must successfully pass the accompanying exam on the Scholar site. Close this presentation and return to the Scholar site. Click the Test and Quizzes tab and select the exam for this module.

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Fertilizer Applicator Certification Training (FACT)

Virginia Cooperative Extension Virginia Department of Agriculture and Consumer Services Virginia Department of Conservation and Recreation

Michael Goatley, Jr. Professor and Extension Turfgrass Specialist Crop and Soil Environmental Sciences Department, Virginia Tech

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