fRATEMASTER SOInstallation InstructionsDate: 11/89Issue: 02

RATEMftSTER 20 INSTALLATION INSTRUCTIONSCONTENTSPageList of Diagrams ............................ iiPacking List ................................ iii1. Introduction ............................ 22. Installation............................ 4i) The Instrument Unit ................ 4ii) Cable Connections .................. 4iii) The Speed Sensor ................... 6a) VJheel Sensor ................... 6b) Radar Sensor ................... 9c) Prop Shaft Sensor .............. 12iv) The Flow Sensor ..................... 14v) The Pressure Control Valve .......... 18vi) The ACI Connection Lead .............. 203. Testinq the Installation ................ 24

KATITW.TKK A t ) UftV ()!•' IMAi'.KAMSPageFig 1. Goix-i.ll Ai i .tinicment ............... 1Fig 2. toil «'in.mi <M/sprayer System .......... 3Fig 3. wii 11II| Connections ................ 5Pig 4. Wheel Sensor Kit .................. 7Fig 5. Wheel Sensor Arrangement .......... 8l''i<l ii. Radar Sensor Installation......... ioPig 7 Prop Shaft Sensor ................. 13Fig 8. Flow Sensor Installation - Full Flow 16Fig 9. Flow Sensor Installation - Part Flow 17Fig 10 Electrical Pressure Control Valve .. 19Fig 11. Specimen ACI Label ................. 22Fig 12. ACI Wit iix| Di.Kjiain ................. 23PACKING LISTREF. NO.COMPONENT DESCRIPTIONQUAN11S/HU/159-2-001 S/BKT/199-1-204 S/FIXING/015 S/STK/159-1-041 S/CBL/159-1-012 S/FIXING/008 S/FSNR/039 S/CBL/TIE/001 S/FIXING/024 S/CBL/133-1-013Ratemaster 20 Head UnitHead Unit Mounting BracketHartlng 6 way Male-Male Connector - GreyHartlng sticker Ratemaster Interface Lead Snap lock Connector M8 x 20 Taptlte bolts Cable Tie - 6" In-IIne Connector Valve Drive LeadRatemaster 20 Operating Instructions Ratemaster 20 Installation Instructions Warranty 4 Guarantee Cards (U.K. only) RDS Sticker2 25 4 1 1 1WL/SNR/KIT : Wheel S/SNR/WM/004 S/BKT/199-2-030 S/BKT/199-2-020 S/MAGNET/002 S/BKT/199-2-007 S/FSNR/940601 S/FSNR/940406 S/FSNR/940203 S/FSNR/940103 S/FSNR/940401 S/FSNR/940301CNTRL/VLV/KIT -1 S/PIPE/WRK/020 S/PIPE/WRK/021 S/PIPE/WRK/022 S/PIPE/WRK/023 S/PIPE/WRK/024 S/PIPE/WRK/015Sensor Kit c.w. two Wheel MagnetsWheel Sensor c.w. CableWheel Sensor ClampWheel Sensor Clamp Support StropWheel Magnet )

Wheel Magnet Mounting Strep)i" UNF x Ii" S.S. Hex Set ) Assombltnli" UNF Nyloc Nut )}" Fibre Washer )i" UNF x 1" Hex Seti" UNF FulI NutJ" Spring WasherControl Valve Kit - 1" 1" Pressure Control Valve 1" Female Tee Piece 1" Male Nipple 1" x 1" HosetalI 1" x Ii" HosetalIIi" Tank Connector c.w. backnut 4 washer1 11 2 2 2 2 2 4 4 41

UT/COMP/20/1 - ContinuedPACKING LISTDATE : 1st July 1989[F. NO. COMPONENT DESCRIPTION QUANTITY■OW/SNRAIT : Flow Sensor Pickup Kit 1'SNR/FLOW/003 Flow Sensor Pickup c.w. 5m flying lead 1'CBL/199-2-003 Flow Sensor Extension Lead - 3m 1'FIXING/024 In Line Connector 2O ONE Of THE FOLLOWING KITS-W/SNR/KT/j" : Flow Sensor Turbine Kit - i"'SNR/FLOW/006 i" Turbine Assembly 1'PIPE/WRK/003 1" Socket 2'PIPE/WRK/016 i" HosetalI 2'PIPE/WRK/027 1" - i" Reducer 2-W/SNR/KT /1" : Flow Sensor Turbine Kit - }"'SNR/FL0W/006 i" Turbine Assombly 1fpIPE/WRK/003 1" Socket 2'PIPE/WRK/007 i" HosetalI 2-OW/SNR/KIT-I" : Flow Sensor Turbine Kit - 1"/SNR/FLOW/004 1" Turbine Assembly 1'PIPE/WRK/023 1" Hosetal I 2LW/SNR/KT/1 j" : Flow Sensor Turbine Ki t - 1 i"/SNR/FLOW/004 1" Turbine Assembly 1/PIPE/WRK/010 IV Hostalls 2LW/SNR/KT /U" : Flow Sensor Turblno Ki t - 1 1"/SNR/FL0W/005 2" Turbine Assembly 1/PIPE/WRK/019 2" - H" Raducer 2/PIPE/WRK/013 Ii" HosetalIs 2/PIPE/WRK/025 2" Socket 2LOW/SNR/KIT-2" : F low Sensor Turblno Ki t - 2"/SNR/FLOW/005 2" Turbine Assembly 1/PIPE/WRK/025 2" Sockets 2/PIPE/WRK/026 2" HosetalIs 2

RATEMASTER 20 INSTALLATION INSTRUCTIONS1. INTRODUCTIONThe Ratemaster 20 is a single instrument incorporating the functions of the Spraymeter 2, Ratemaster and Area Compensation Interface all housed together in a single enclosure.This system is a very comprehensive unit providing information to the sprayer operator and full automatic volume control. Fig 2 illustrates how the Ratemaster 20 integrates with the sprayer.The information displayed is:-Forward Speed of the vehicle in km/hr or mph Total Area covered in hectares or acres Partial (Trip) Area covered in hectares or acres Partial (Trip) Volume of liquid sprayed in litres or gallonsTotal Volume of liquid sprayed in tens of litres or tens of gallonsActual Application Rate at any particular moment in litres/ha or galls/acreTarget Application Rate in litres/ha or galls/acreThe Ratemaster 20, in its Automatic mode, regulates the sprayer output by means of a pressure regulating valve. Alternatively, used in the manual mode, the Ratemaster 20 gives the operator finger-tip control of spraying pressure and application rate.The Area Compensation Interface incorporated in the unit interfaces with the sprayer switch box to ensure that area and application rate are correctly calculated when individual sections of the boom are switched off.i) ii) iii) iv)vi) vii)The various components utilised in the system are:i) The instrument unit mounted on its bracket in the <mI.ii) The Cable Connectionsiii) One of three types of forward speed sensor. Either:a) Wheel Sensorb) Prop Shaft Sensorc) Radar Sensoriv) The Flow Sensorv) The Pressure Control Valvevi) The ACI Interface LeadYou are recommended to read through the installatior instructions in their entirety and then to work througl each section in sequence.Fig. 2. Ratemaster/Sprayer SystemRATEMASTER SOBOO E3 BOOC=LTr 3SPEED SENSORRDS

DOPPLER SENSOR (OPTION)A|J FLOWELECTRONICSENSOR/ I \ \ / I .SPRAY BOOM/ \ N / / V \IT3

\ s w- 7 -

I . INSTALLATIONi) The Instrument UnitThis should be mounted in its bracket in the cab where it is accessible to the operator but not in such a position where it will obstruct him or his view. A suitable position is usually available above the brake pedals or suspended from the cab roof. The bracket is bolted in position using two 5/16" UNF Tap-Tite bolts. The Tap-Tite bolts require a hole drilled to 9/32" diameter.11) Cable Connectionsa) Hartlng Connector. Fig. 3I lie Ratemaster 20 is fitted with two flying leads terminating in 6 way female Harting connectors. The grey connector is used for all vehicle features, the blue connector is used for the sprayer features. See fig 3.All individual cables are connected to a mating 6 way male-male connector which in turn plugs into the female connector on the flying lead.The individual cables must be coupled to the shell ' correctly. Orientation is identified by a chamfered corner on the bottom right and a tooth in the top centre. It will be easier to identify the connections by fitting the male-male shell onto the flying lead first. The plain ends of the shell must be towards the instrument, the labelled ends towards the machine.Wiring ConnectionsCable From: Cable Colour: To Connector: Terminal:Power +12v Brown Grey 4

Supply Ov Blue Grey 1Speed + Brown Grey 5Sensor Ov Blue Grey 2Cut-Out +■ Brown Grey 6

Ov Blue Grey 3Control + Brown Blue 4Valve - Blue Blue 1

Flow + Brown Blue 6Sensor Ov Blue Blue 3

CD

iii)The Speed SensorWheel Sensor Kit The Wheel Sensor is the cylindrical stainless steel sensor. It is operated by a magnet or magnets, on the wheel passing the end of the sensor.When used as a speed sensor, it is normally fitted to the front wheel of the vehicle as this is generally of smaller diameter than the rear and suffers less slip.It is installed, in its clamp, on a bracket so that the magnet, fixed to the wheel or wheel hub passes within 25 mm (1") of the end of the sensor. The sensor should protrude at least 20 mm beyond any part of the clamp or surrounding steelwork. (See Fig 4).The Wheel Sensor Clamp Support Bracket should be cut and bent to a suitable shape to enable this arrangement. The bracket can be welded or bolted to the underside or inside face of the kingpin assembly. Ensure that, if it is a steering wheel, the full lock can be achieved without interference.The sensor will be better protected if it is installed behind the axle.Use the cable ties supplied to attach the sensor cable to the axle, making sure that the steering or the pivoting of the axle cannot stretch or pinch the cable. The cable should be run along a well protected path by securing it to existing cables, to hydraulic pipes, or in existing trunking. Take the cable up to the 6 way Harting connector. Connect the blue lead to terminal 2 in the grey connector and the brown lead to terminal 5.The wheel magnets. Normally two magnets, mounted on their straps are fixed to the wheel hub or wheel dish. The maqnets must be mounted exactly opposite each other. TheWL/SNR/KIT - WHEEL SENSOR KIT C.W. 2 MAGNETS1. S/SNR/WM/0012. S/BKT/199-1-0303. S/BKT/199-1-0314. S/MAGNET/0025. S/BKT/199-2-007Wheel SensorWheel Sensor ClampWheel Sensor Clamp Support BracketWheel MagnetWheel Magnet Mounting Strap

_ ft -straps can be cut, bent and welded as appropriate to ensurt that each magnet passes the end of the wheel sensor. It is often convenient to use two of the wheel studs to secure the magnet strap. Alternatively the magnets can be bolted directly to the wheel. In this case ensure that the locknuts are used and that they are not overtightened as the magnet can be shattered.If the vehicle has particularly large wheels or if the typical operating speed is very slow, it may be necessary to fit extra magnets. These are available as spare parts from RDS. When fitting extra magnets it is important that they are equally spaced around the wheel.Radar Sensor Kit - OptionThe RDS Radar 400 Sensor operates by directing a signaL beam onto the ground as the vehicle is travelling. The characteristic of the beam reflected from the ground varies with the forward speed of the vehicle.The sensor must be mounted in its bracket so that it is pointing at an angle of 45° to the ground. This angle is critical to the accuracy of the instrument.The sensor will operate equally effectively whether it is pointing forwards or backwards. The mounting position should be on a rigid part of the vehicle as any vibration will be mistaken by the sensor as speed.It is recommended that the sensor is positioned about half a metre above the tallest crop in which it will operate. Alternatively it can be situated about half a metre or morn.; above the ground, following in the vehicle wheel tracks, BUT NOT POINTING DIRECTLY AT THE WHEEL.

- in -The radar beam is transmitted over an angle of 30° either side of the centre line (i.e. an included angle of 60°). The sensor should ideally be mounted so that this transmission area is free of any moving part of the vehicle, i.e. wheels, beam axle, or steering linkage.The mounting bracket has four fixing holes in it. The bracket must be fixed to the vehicle so that two holes are parallel to the ground surface and two are perpendicular to the ground surface. (See Fig. 5.)If the vehicle is standing on perfectly level ground the hole positions can be marked by using a plumb line to give a true vertical line. Otherwise a tee-square must be used to give a line perpendicular to the ground surface.Sensor CableThis is a four-core cable with a screw-in alloy (Jaeger) connector on one end and V crimp terminals on the other. The cable designations are as follows:Jaeger Socket1 Blue Ov (Earth)2 Red +12v3 Yellow 1 pulse per metre signal4 Green 46 pulses per metre signal1 2 3 6This cable is normally used with the Radar 400 sensor. Only 3 cores are used, 1, 2 and either 3 or 4. Core 4 is only used for Speedmeter 400RR, core 3 is used with all other instruments.

The Radar 400 sensor is normally connected to the grey connector shell as follows:Harttag Terminal1 Earth 12 +12v 43 Signal 5Any other cores must be cut off and not connected. Prop Shaft Sensor - OptionOn some vehicles it is more practical to use a magnetically operated sensor on the prop shaft, drive shaft or half shaft of the vehicle. This can be installed on any exposed shaft which rotates at a speed proportional to ground speed i.e. When there is no variable gear or drive ratio between the shaft and the wheel.The plastic iroulded magnet carrier sits on the shaft and is secured by two nylon cable ties. If the shaft is likely to be exposed to severe impacts it is advisable to use a hose clip in place of the cable ties.*'The sensor is the 12mm diameter x 45mm long threaded cylindrical unit. It is held and secured in its bracket by the two nylon M12 nuts. At least 20mm of the sensor must protrude clear of the fixing nuts. Otherwise the sensor and bracket can be arranged as convenient to ensure that the magnet passes the sensor in any one of the relationships shown in Fig. 6.Fig.7 Prop Shaft Sensor KitPROP/SHAFT/KIT - Prop Shaft Sensor Kit1. S/SNR/SSM/002 Shaft Speed Sensor. Cylindrical2 . S/BKT/199-2-007 Sensor Mounting Bracket3 . S/MGNT/CRRY/003 Saddle Mounted Magnet Carrier4 . S/FIXING/006 Hose Clip- 12 -

iv) The Flow SensorThis is installed in the pipework of the sprayer at a point which will measure the quantity of liquid being applied to the field.Sprayers normally conform to the configuration of Figure 8 or 9. With either configuration, the sensor must be installed at position A. Do not instal at position B since this will give inaccurate readings. With the Full Flow Measurement system as per Figure 8, the whole flow is being measured, this is the best method possible. However, on some sprayers the pressure control valve block and individual boom outlets are inseparable. In these instances the One Boom Flow Measurement System as per Figure 9 must be used.Five Turbine sizes and six hose fitting sizes are available. Having established the position in which the sensor can be installed, ensure that you have ordered and have been supplied with the correct sensor.Hose Size Turbine Size Calibrated Flow Range h" h" 3-30 l./min 0.66-2.20 galls/minh" h" 8-80 l./min 2-18 galls/min1" 1" 20-170 l./min 4 -̂40 galls/minIk" 1" 20-170 l./min 4*5-40 galls/minIV 1%" 35-350 l./min 8-80 galls/min2" 2" 50-500 l./min 11-110 galls/minIf you are in doubt about the flow rate through the sensor, this is calculated as follows:- 13 -Flow Rate (Litre/min) =km/hr x litres/hectare x nozzle spacing (m) x no of nozzles 600Flow Rate (galls/min) =m.p.h x galls/acre x nozzle spacing(ins) x no of nozzles —~-5930"The sensor housing is normally screwed or hose clipped to the sprayer pipework. Use PTFE tape on all screw threads.Points to remember about the Flow Sensor:1. The sensor will fit into either port of the flow sensor body. Ensure that whichever port is used the flange on the sensor goes right down to the shoulder on the port. On the \" Turbine, use the port with the flat bottom which is the deeper port.2. The sensor should be installed wherever possible with 10 diameters of straight pipe upstream and 5 diameters of straight pipe downstream of the sensor. This minimises the turbulence in the sensor area.3. A 100 micron filter upstream of the sensor is desirable to ensure long life for the turbine bearings.4. The sensor turbine should be inspected and cleaned regularly to ensure that the turbine is running freely. Do not allow liquid to remain in the sensor line when the sprayer is not in use. This is particularly important if there is a danger of freezing.

Fig.8 Flow Sensor Installation - Full Flowto SpraymeterFlow Sensor In Full Flow

Use the two core extension lead if necessary to lengthen the lead to the Spraynieter. It is important that the cable colour is followed. An In-Line Connector can be installed at the rear of the tractor cab if necessary.Connect the brown core to the blue Harting connector terminal 6 and the blue core to terminal 3.v) The Pressure Control Valve The flow rate of the sprayer is controlled by means of an electrically operated valve. This valve is situated in a return line between the main spray pressure line and the tank. A tee piece is inserted at any convenient point between the pump and the boom section valves.There are two sizes of valve available, 1" and 2" diameters. As a general rule the 1" is adequate for all positive displacement (piston or diaphragm) pumps and the 2" valve should be used with centrifugal pumps or very high output pumps.The standard pressure regulating device of the sprayer must be left in the system to act •• as a maximum pressure regulator.A return hose must be installed from the butterfly valve to the top of the tank. This return should be unique to the control valve and must be a free, unrestricted entry into the tank. A drop pipe may be required inside the tank to prevent frothing.The valve is operated by a two core cable. This cable should be routed via a well protected path from the sprayer to the Ratemaster.

In Line ConnectorIf a quick mate connector is required in a two-core cable, e.g. rear of tractor cab, the inline connector may be used.Cut the cable and strip back the outer sheath to at least 30mm. Do not strip the individual conductors.Open the connector cover r ight out. Place the individual cores in the connector tucking the wire right into the slots below the hinge. Pack the connector with petroleum jelly or grease to protect it from corrosion.Squeeze the cover closed using a pair of pliers or a vice. Ensure the cover is fully closed and the barbed clips are home.Prepare and assemble the mating connector in the same way ensuring that when connected, the cable polarity is correct.Use petroleum jelly (vaseline) or, grease to protect all exposed connections from corrosion. This isparticularly important if liquid fertilizer is used. Try to prevent a connector appearing at a low point of a cable run or underneath the sprayer as spilt liquid may run into them.Connect the valve drive cable to the Ratemaster Composite 'Harting' connector, blue core to terminal 1 brown core to terminal 4.vi) The ACI Connector Lead On the rear of the Ratemaster 20 there is a 12 way BICC connector. An interface lead plugged into this connector goes to the Sprayer Switch Box and connects into it.- ?n A label on the back of the Ratemaster 20 gives details of the ACI programme installed in the unit and shows the number of nozzles which will be identified by each of the coloured leads. Up to 9 boom sections can be identified. Use only the colours appropriate for the sprayer in question.The interface cable should be connected into the sprayer switch box via a gromrnetted hole and wired as follows:i) Master On-Off. The black lead with female push on must be connected to earth when the Master On-Off switch of the implement is in the Off position.The ACI black lead can be earthed through a high resistance load e.g. Light bulb or solenoid coil when the sprayer of boom section is switched off. The ACI black lead can be safely connected to a 12v supply when the sprayer or boom section is switched on. Connect the black lead using a solder joint, screw terminal or snap lock connector as appropriate following the general diagram shown in figure 1.•N.B. The black lead must be connected to earth when the flow through the flow sensor is switched off.If the flow sensor is in the full flow, then the master on-off switch can be used. If the flow sensor is only in one boom section then the black lead to the ACI must be connected via that boom section switch.

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ii) Coloured Cables From the code table on the rear of the Ratemaster Composite select which cables are required for the particular boom arrangement of the sprayer.These cables must be connected to the individual boom switches in the switch box so that they are at +12v when that boom section is switched on. Use the snap lock connectors to couple the individual wires to the boom switch cables.NB. On sprayers with rotary ball valves and 3 wire cables, ensure that there is 12v on the connection point continuously when the boom section is switched on.Fig. 11. Specimen ACI Labelbe 02ACI REF:CableRd Or

Yw Gn Tq

Vt Gy Wi Pk

Blac Brow

k on-ofl ■n + 1 2 v Blue Ov

- 52 -Fig. 1 2 ACI WIRING DIAGRAMTo Hart ingVACIACI Mul t icorc- 18 -

3. Testing the Installation The following procedure is a basic functional test simply to establish whether each part of the installation is correctly installed. It does not cover calibration of the system nor the sprayer.Refer to the operating instructions for the calibration procedure.i) Power. Switch the vehicle ignition on and switch the Ratemaster on at the switch on the back panel of the unit. The digital displays on both instruments will be on and the displays will be illuminated.Both instruments should already be programmed with a set of test data to enable the functional test to be carried out.ii) Switch Box Interface. Ensure that there is power to the sprayer switch box. Switch the sprayer on-off switch 'on' and all the boom section switches 'on' Press the V switch on the Spraymeter until the chevron on the display is above position 6. Now press the letter "M" of Ratemaster. The display will show the number of nozzles that are switched on at that moment followed by a letter r or n. If all the boom section switches are on, the number should be the number of nozzles on the full boom.Release the "M" . Switch one of the boom sections off. Wait 2 or 3 seconds before pressing the "M". The display should have changed to show the appropriate reduced number of nozzles.Repeat with all combinations of boom switches.iii) Forward Speed Select channel 1 on the Spraymeter. Drive the vehicle forward and a speed should be displayed. It will not be correct until the Spraymeter has been calibrated.iv) Area Select channel 2 or 3 on the Spraymeter. Continue to drive the vehicle. If the sprayer switches are on, area should accumulate. If the master on-off switch is switched off, or all the boom switches are switched off, the area accumulation should stop.v) Flow Ensure that the sprayer is correctly prepared and fit to run. Partially fill the sprayer tank with water and engage the sprayer pump.Select channel 4 or 5 on the Spraymeter. Start the sprayer operating and flow should accumulate on the Spraymeter.vi) Manual Pressure Control Set the Ratemaster to 'Manual' by pressing the Man/Auto switch until the chevron appears above the Manual index. With the sprayer running, press and hold either the + or - switches. The pressure should increases or decrease whilst the switch is held. (At this stage it does not matter if the + switch decreases pressure and the - switch increases pressure).All the sensors and functions have now been tested and the system is ready for calibration.- 19 -