fRATEMASTER SO

Installation Instructions
Date: 11/89
Issue: 02

RATEMftSTER 20 INSTALLATION INSTRUCTIONS

CONTENTS
Page
List of Diagrams ............................ ii
Packing List ................................ iii
1. Introduction ............................ 2
2. Installation............................ 4
i) The Instrument Unit ................ 4
ii) Cable Connections .................. 4
iii) The Speed Sensor ................... 6
a) VJheel Sensor ................... 6
b) Radar Sensor ................... 9
c) Prop Shaft Sensor .............. 12
iv) The Flow Sensor ..................... 14
v) The Pressure Control Valve .......... 18
vi) The ACI Connection Lead .............. 20
3. Testinq the Installation ................ 24

KATITW.TKK A t ) UftV ()!' IMAi'.KAMS

Page
Fig 1. Goix-i.ll Ai i .tinicment ............... 1
Fig 2. toil 'in.mi <M/sprayer System .......... 3
Fig 3. wii 11II| Connections ................ 5
Pig 4. Wheel Sensor Kit .................. 7
Fig 5. Wheel Sensor Arrangement .......... 8
l''i<l ii. Radar Sensor Installation......... io
Pig 7 Prop Shaft Sensor ................. 13
Fig 8. Flow Sensor Installation - Full Flow 16
Fig 9. Flow Sensor Installation - Part Flow 17
Fig 10 Electrical Pressure Control Valve .. 19
Fig 11. Specimen ACI Label ................. 22
Fig 12. ACI Wit iix| Di.Kjiain ................. 23
PACKING LIST
REF. NO.
COMPONENT DESCRIPTION
QUAN11
S/HU/159-2-001 S/BKT/199-1-204 S/FIXING/015 S/STK/159-1-041 S/CBL/1591-012 S/FIXING/008 S/FSNR/039 S/CBL/TIE/001 S/FIXING/024 S/CBL/133-1013
Ratemaster 20 Head Unit
Head Unit Mounting Bracket
Hartlng 6 way Male-Male Connector - Grey
Hartlng sticker Ratemaster Interface Lead Snap lock Connector M8 x 20 Taptlte
bolts Cable Tie - 6" In-IIne Connector Valve Drive Lead
Ratemaster 20 Operating Instructions Ratemaster 20 Installation Instructions
Warranty 4 Guarantee Cards (U.K. only) RDS Sticker
2 25 4 1 1 1
WL/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/940301
CNTRL/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/015
Sensor Kit c.w. two Wheel Magnets
Wheel Sensor c.w. Cable
Wheel Sensor Clamp
Wheel Sensor Clamp Support Strop
Wheel Magnet )

Wheel Magnet Mounting Strep)

i" UNF x Ii" S.S. Hex Set ) Assombltnl
i" UNF Nyloc Nut )
}" Fibre Washer )
i" UNF x 1" Hex Set
i" UNF FulI Nut
J" Spring Washer
Control Valve Kit - 1" 1" Pressure Control Valve 1" Female Tee Piece 1" Male
Nipple 1" x 1" HosetalI 1" x Ii" HosetalI
Ii" Tank Connector c.w. backnut 4 washer
11
122222444
1

UT/COMP/20/1 - Continued
PACKING LIST
DATE : 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 2
O 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 1
fpIPE/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 2
LW/SNR/KT/1j" : Flow Sensor Turbine K i t - 1 i"
/SNR/FLOW/004 1 " Turbine Assembly 1
/PIPE/WRK/010 I V Hostalls 2
LW/SNR/KT/U" : Flow Sensor Turblno K i 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 2
LOW/SNR/KIT-2" : F l o w Sensor Turblno K i t - 2"
/SNR/FLOW/005 2" Turbine Assembly 1
/PIPE/WRK/025 2" Sockets 2
/PIPE/WRK/026 2" HosetalIs 2

RATEMASTER 20 INSTALLATION INSTRUCTIONS

1. INTRODUCTION
The 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 gallons
Total Volume of liquid sprayed in tens of litres or tens of gallons
Actual Application Rate at any particular moment in litres/ha or galls/acre
Target Application Rate in litres/ha or galls/acre
The 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 Connections
iii) One of three types of forward speed sensor. Either:
a) Wheel Sensor
b) Prop Shaft Sensor
c) Radar Sensor
iv) The Flow Sensor
v) The Pressure Control Valve
vi) The ACI Interface Lead
You are recommended to read through the installatior instructions in their entirety and then to work
througl each section in sequence.
Fig. 2. Ratemaster/Sprayer System
RATEMASTER SO
BOO E3 BOO
C=
LT
r 3
SPEED SENSOR
RDS

DOPPLER SENSOR (OPTION)

A
|J FLOW
ELECTRONIC
SENSOR

/
I
3
IT
\sw
-7-

.SPRAY BOOM/

N /

V\

I . INSTALLATION
i) The Instrument Unit
This 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 Connections
a) Hartlng Connector. Fig. 3
I 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 Connections
Cable From:
Cable Colour: To Connector: Terminal:
Power
+12v
Brown
Grey
4
Supply
Speed
Sensor
Cut-Out
Control
Valve

Ov
+
Ov
+
Ov
+
-

Blue
Brown
Blue
Brown
Blue
Brown
Blue

Flow + Brown Blue 6

Sensor Ov Blue Blue 3
CD

Grey
Grey
Grey
Grey
Grey
Blue
Blue

1
5
2
6
3
4
1

iii)The Speed Sensor

Wheel 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. The
WL/SNR/KIT - WHEEL SENSOR KIT C.W. 2 MAGNETS
1. S/SNR/WM/001
2. S/BKT/199-1-030
3. S/BKT/199-1-031
4. S/MAGNET/002
5. S/BKT/199-2-007
Wheel Sensor
Wheel Sensor Clamp
Wheel Sensor Clamp Support Bracket
Wheel Magnet
Wheel 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 - Option
The 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 DIRECTLYATTHE 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 Cable
This 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 Socket
1 Blue Ov (Earth)
2 Red +12v
3 Yellow 1 pulse per metre signal
4 Green 46 pulses per metre signal
12 3 6
This 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 Terminal
1 Earth 1
2 +12v 4
3 Signal 5
Any other cores must be cut off and not connected. Prop Shaft Sensor - Option
On 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 Kit
PROP/SHAFT/KIT - Prop Shaft Sensor Kit
1. S/SNR/SSM/002 Shaft Speed Sensor. Cylindrical
2 . S/BKT/199-2-007
Sensor Mounting Bracket
3 . S/MGNT/CRRY/003
Saddle Mounted Magnet Carrier
4 . S/FIXING/006 Hose Clip
- 12 -

iv) The Flow Sensor

This 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/min
h" h" 8-80 l./min 2-18 galls/min
1" 1" 20-170 l./min 4^-40 galls/min
Ik" 1" 20-170 l./min 4*5-40 galls/min
IV 1%" 35-350 l./min 8-80 galls/min
2" 2" 50-500 l./min 11-110 galls/min
If 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
600
Flow 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. A100 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 Flow
t o S p r ay me t e r
Flow 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. Atee 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. Adrop 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 Connector
If 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
is
particularly 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.

- 21 -

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 Label
be 02
ACI REF:
Cable
Rd
Yw Gn Vt Gy Wi
Or
Tq
Pk
k on-ofl
Blac n
Brow + 1 2 v
Blue Ov
- 52 Fig. 1 2
ACI WIRING DIAGRAM
To H a r t i n g
V
ACI
ACI Multicorc
- 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 onoff 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 -