Standard Version REFERENCE MANUAL

Transcription

1 R o a d M a s t e r TM Standard Version REFERENCE MANUAL

2 R o a d M a s t e r TM Standard Version reference MANUAL The RoadMaster is an electronic control system that can help you operate more cost-effectively by providing the information you need to maintain proper application rates of liquid de-icer and anti-icing chemicals. The RoadMaster has been designed for easy installation and operation. However, since each installation will vary depending on your equipment, please take time to familiarize yourself with this manual and the actual components before beginning. Following the procedures described in this manual will ensure proper performance and help avoid problems or questions once you are on the road. This manual is written for the RoadMaster. Please read the manual carefully and follow the instructions as they apply to your usage. If you do encounter a problem that cannot be corrected by reviewing this manual, consult Micro-Trak Systems, Inc. for assistance. P. O. Box East Leray Avenue Eagle Lake, MN Fax: trakmail@micro-trak.com Copyright 2007 Printed in the U.S.A. 2

3 Micro-Trak Warranty Micro-Trak (herein Seller ) warrants to the original purchaser (herein Buyer ) that, if any product or part of the product (herein part ) proves to be defective in material or workmanship, upon inspection and examination by Seller, within one (1) year from the original date-of-purchase, and is returned to Seller with dated proof-of-purchase, transportation prepaid, within thirty (30) days after such defect is discovered, Seller will, at their option and sole discretion, either repair or replace said part, except that the warranty for expendable parts, including but not limited to, light bulbs and batteries shall be thirty (30) days from the original date-of-purchase. Said warranty is valid only when the part has been installed, operated and maintained in strict accordance with the procedures outlined in the manual. Any damage or failure to said part resulting from abuse, misuse, neglect, accidental or improper installation or maintenance, unauthorized modification, use with other products or attributable to acts of God, as determined solely by the Seller, will invalidate the warranty. Said part will not be considered defective if it substantially fulfills the performance specification. Buyer shall be responsible for all maintenance services, if any, all in strict accordance with the procedures outlined in the manual. The warranty does not include labor, installation, replacement parts or repairs, delivery of replacement parts or repairs or time and travel. Said warranty is nontransferable. The foregoing warranty is exclusive and in lieu of all other warranties of merchantability, fitness for purpose and of any other type, whether express or implied. The Seller s liability, whether in contract, in tort, under any warranty, in negligence or otherwise, shall not exceed the return of the amount of the purchase price paid by the Buyer, and under no circumstance shall the Seller be liable for special, indirect or consequential damages. Seller neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said part. No action, regardless of form, arising out of the transactions under this agreement may be brought by the Buyer more than one (1) year after the cause of action has occurred. Seller agrees to extend the term of the foregoing warranty period should the Buyer return completed warranty registration information, with dated proof-of-purchase, to the Seller within one (1) year from the original date-of-purchase. All conditions and limitations of said foregoing warranty, except the term of said foregoing warranty, shall apply. Said term shall be extended to a total of three (3) years from the original date-of purchase on display consoles and network communication modules, as defined by Seller, and said term shall be extended to a total of two (2) years from the original date-of-purchase on all other parts, except that the warranty for expendable parts, including but not limited to, light bulbs and batteries shall be thirty (30) days from the original date-of-purchase, and except that the warranty for parts manufactured by someone other than the Seller, including but not limited to, shut-off and control valves, DGPS receivers, memory cards and drives, mapping software, flowmeters and pressure sensors shall be one (1) year from the original date-of-purchase. Buyer accepts these terms and warranty limitations unless the product is returned to Seller, via proper distribution channels and approved return authorization, with dated proof-of-purchase, transportation prepaid, within fifteen (15) days from the date-of-purchase for refund of the purchase price. Units under warranty should be sent prepaid, with dated proof-of-purchase, within 30 days of discovering defect, to the address below: MAIL and UPS: Micro-Trak Systems, Inc. Attn: Service Department 111 East LeRay Avenue Eagle Lake, MN Extended Warranty Option It s simple! Just complete the enclosed registration card(s) for this product and mail it in and we ll extend your warranty for up to three years*, at no additional charge. MAIL IN YOUR REGISTRATION CARD(S) TODAY! Registration Card information is for internal use only. * Some limitations apply. See warranty statement for details. At Micro-Trak Systems, we believe a product that delivers quality and performance at a low cost is what is needed to help today s operator and the operator of the future compete in the world mar ket. It is our goal to provide operators with a line of electronic equipment that will help build and maintain an efficient and profitable operation that can be passed on to future generations. We thank you for your purchase and hope that we can be of service to you in the future. Micro-Trak Systems, Inc. 3

4 Table of Contents Warranty... 3 Table of Contents Component Parts and Assembly Hardware... 6 RoadMaster System Diagram... 7 RoadMaster Wiring Diagram... 8 Installation Mounting the Display Console...9 Attaching the Power and Run/Hold Control Switches...10 Electrical Installation...10 RoadMaster Std Boom Connections...10 Speed Sensor Installation...11 Speed Sensor Options...11 Mounting and plumbing flowmeter...11 Installing flow sensor cable...12 Installing Servo Valve...12 Installing Optional Tank Level Switch...12 Installing External Blast Switch...12 RoadMaster Console Functions Calibration Entering Calibration Values...14 flow Cal, Min Flow, Adjust Rate, Target Rate, Width Cal, Speed Cal, Mode Sel Radar or GPS Speed Sensor Calibration Table...16 Test Speed...16 Exiting Calibration...16 Default Calibration Values...16 Calibration Log Sheet...17 Special Calibration Entering Special Cal Values...18 Special Cal Pages...18 Default Special Calibration Values...18 Page One Fill Tank Size, Tank Alarm Set Point, Blast Duration, Blast Target Rate, Units (English or Metric), Vehicle Number, Valve Polarity, Valve Speed...19 Page Two Alarm Minimum Speed, Start Time, Auto Shut Off, Auto Delay Time, Set Year, Set Month, Set Date, Set Time...20 Page Three Manual Enable, Alarm Enable...21 Operation Console Power/System On/Off, Display, Run/Hold Switch, Auto/Man Button, Blast Button, + and - Buttons, Boom Switches, Warning Device, Audible Alarm, Rotary Switch, Emergency Stop Rotary Switch Positions volume, Volume/Minute, Tank Level, Serial Port, rate, Area, Distance, Mode, Speed Resetting System Counters...25 Pre-Application System Checkout

5 Table of Contents (cont) Troubleshooting Messages/Warnings...27 Console Appears Dead...28 Speed is Always Zero or Erratic...28 Area Count is Inaccurate...28 Distance Count is Inaccurate...28 No Readout of Gallons (liters) or Gallons per Minute (liters per minute)...28 Total Liquid Used is Inaccurate...28 Electrical Interference...28 Displayed Measurements do not Make Sense...28 Display Reads OFL...28 Checking Individual Components...29 console Inputs...29 Speed Input...29 Flow Input...29 Tank Switch Input...29 Run/Hold Input:...29 Harness...29 Magnetic Hall-Effect Speed and Flow Sensors...29 Astro II and Astro vansco Radar Speed Sensor...29 Electric Boom Values...29 Plumbing...29 Plumbing Guidelines General...30 Pump Inlet...30 Flowmeter...30 Pump...30 Appendices Appendix A: Optional speed sensor mounting installation Appendix B: Calibrating if Using a Magnetic Speed Sensor...35 Appendix C: Fine Tuning Speed/Distance Calibration Value...36 Appendix D: Fine Tuning Flowmeter Calibration Value...37 Appendix E: Flowmeter Assembly...38 Appendix F: Radar "Y" Adapter Cables...39 Appendix G: Conversion Chart...40 Appendix H: Data List for Data Logging On-The-Go...41 Appendix I: Totals Data List for Downloading Accumulated Data...42 Appendix J: Replacement Parts List

6 Component Parts and Assembly Hardware Before beginning installation, check the carton contents for the following items: ROADMA S T E R Standard Version (2) (2) RoadMaster Console P/N (2) (2) (2) (2) (2) Console Mount Kit P/N REFERENCE MANUAL Reference Manual P/N Battery Cable with Fuse Holder & Ring Terminals P/N pin M/P Extension Cable P/N Branch Cable P/N Cable, Remote Hold/Blast P/N Kit, Run/Hold Switch P/N Kit, Power Switch P/N Optional Blast/Run/Hold Remote Switch Box P/N

7 Roa d Mas t e r System Diagram RUN/HOLD BLAST GRAY TIE P/N GND P/N P/N VDC GND P/N OPTIONAL TANK LEVEL SWITCH P/N P/N P/N YELLOW TIE P/N YELLOW TIE P/N GND (BLACK) P/N V (WHITE) BOOM 3 (ORANGE) BOOM 2 (RED) BOOM 1 (BROWN) P/N GREEN TIE 7

8 Roa d Mas t e r Wiring Diagram RoadMaster Console BRN RED ORG YEL GRN BLU VIO GRY WHT BLK BRN RED ORG YEL BLU VIO GRY WHT BLK BOOM 1 BOOM 2 BOOM 3 SERVO + SERVO - SIGNAL POWER GND VES OUT GND +VES POWER SIGNAL GND TANK SIG TANK GND SWITCHED VES +VES GROUND BLK GND WHT +10V GRN BLAST RED HOLD HOLD/BLAST P/N GA. BRN 16 GA. RED 16 GA. ORG 20 GA. YEL 20 GA. BLU 20 GA. VIO 20 GA. GRY 16 GA. WHT 16 GA. BLK YELLOW TIE GRAY TIE 20 GA. BRN 20 GA. RED 20 GA. ORG 20 GA. YEL 20 GA. GRN 20 GA. BLU 20 GA. VIO 20 GA. GRY 20 GA. WHT 20 GA. BLK REMOTE BLAST GND A 3-PIN B M/P 150 C TOWER 3-PIN A M/P 150 B SHROUD C A 2-P W/P B 150 SHROUD 2-P W/P 150 TOWER A 3-PIN B M/P 150 C TOWER 3-PIN M/P 150 SHROUD A 3-PIN B M/P 150 C TOWER 3-PIN M/P 150 SHROUD A 2-P M/P B 150 TOWER 2-P M/P 150 SHROUD 10 FT. EXTENSION, P/N A B C D E F G H J K 10-PIN METRI-PACK SHROUD 10-PIN METRI-PACK TOWER A B C D E F G H J K 16 GA. BRN 16 GA. RED 16 GA. ORG 20 GA. YEL 20 GA. GRN 20 GA. BLU 20 GA. VIO 20 GA. GRY 16 GA. WHT 16 GA. BLK A B A B C A B C A B 18 GA. RED 18 GA. BLK POWER CABLE, P/N GA. ORG 14 GA. BLU 180 OPTIONAL TANK LEVEL SWITCH INPUT 18 GA. RED 18 GA. WHT 18 GA. BLK 120 HALL EFFECT MAGNET WHEEL SENSOR KIT, P/N GA. RED 18 GA. BLK A B C D E F G H J K 10-PIN METRI-PACK SHROUD 10-PIN METRI-PACK TOWER A B C D E F G H J K 16 GA. BRN 16 GA. RED 16 GA. ORG 20 GA. YEL 20 GA. GRN 20 GA. BLU 20 GA. VIO 20 GA. GRY 16 GA. WHT 16 GA. BLK BOOM SERVO, CABLE, P/N RUN/HOLD SWITCH BRACKET KIT, P/N VES GND FUSE HOLDER, 10A FUSE 5/16 RING CONN (2X) A 3-PIN B M/P 150 C TOWER POWER SWITCH BRACKET KIT, P/N YELLOW TIE A 3-PIN W/P BC SHROUD SERVO A 3-PIN M/P BC TOWER GREEN TIE GRD BRN RED ORG BOOM 1 BOOM 2 BOOM 3 12 VDC 8

9 Installation Mounting the Display Console Select a mounting location which seems most workable, and best fits your needs. It should be convenient to reach and highly visible to the operator. Do not install in a position that obstructs the view of the road or work area. Whenever possible, avoid locations that expose the console to direct sunlight, high temperature, strong chemicals or rain. Place the mounting bracket in the selected location, mark holes, drill 1/4 (7mm) holes and mount bracket with bolts, lock washers and nuts provided. (Use self-tapping screws if not practical to use bolts.) See Illustration 1. Put rubber washers on carriage bolts and put the bolts through the bracket holes from the inside out. Place console over carriage b olt heads. Install the switch brackets over the carriage bolts and alongside the console bracket. Install the mount knobs on the carriage bolts and tighten to secure the console and switch brackets in place. See Illustration 2. Install the switches in the brackets and attach the quick disconnects on the switch harnesses to the switches (see wiring diagram). Then install the switch harness connectors into the mating connectors on the console harness. Typically the power on/off switch (Kit 14360) is mounted on the left and the run/hold switch (Kit 14361) is mounted on the right. Drill ¼ (7mm) holes for bolts, or 3/16 (5mm) holes for selftapping screws. Mount Knobs Rubber Washers Bolts Lockwashers and nuts Carriage Bolts Illustration 1 Illustration 2 Switch Bracket Console Power Switch Bracket Illustration 3 2-Pin Connector Micro-Trak Switch Bracket Kit - P/N

10 Installation (cont) Electrical Installation Connect the power to the RoadMaster console by plugging the 2-pin W/P tower on the power cable into the 2-pin W/P shroud of the display console. NOTE: The RoadMaster must be connected to a 12-volt DC negative ground electrical system. POWER/BATTERY CONNECTION Locate the power cable for the RoadMaster and route to the battery. When routing cable to console, avoid areas where the cable may be subjected to abrasion or excessive heat. Attach the BLUE wire (ground) to a screw or bolt on the equipment frame. See Illustration. Be sure there is a good metal-to-metal contact. Connect the ORANGE wire to the positive battery terminal. Hot (ORANGE) 10-Amp In-line Fuse Required +12 VDC (RED) Ground (Blue) RoadMaster Boom Connections BOOM SHUT-OFF VALVES Locate solenoid boom valve wires. Connect cables to appropriate booms. Apply silicone grease to solenoid terminals to avoid corrosion. Connect ground wire tabs to ground connections on valves. NOTE: 16-guage WHITE wire is auxiliary power for use with motorized ball valves ONLY. Tie back and tape off to avoid shorting (if not used). NOTE: When using the system in LANE MODE, the center Boom section defines the Lane Width. If only using one Boom section valve, connect the RED wire to it and use the center Boom switch on the console to control it. 3 ORANGE 2 RED 1 BROWN GROUND (BLACK) 120 IN..250 QD FEMALE (7X) BRN BOOM 1 RED BOOM 2 10-PIN METRI-PACK TOWER A B C D E F G H J K 16 GA. BRN 16 GA. RED 16 GA. ORG 20 GA. YEL 20 GA. GRN 20 GA. BLU 20 GA. VIO 20 GA. GRY 16 GA. WHT 16 GA. BLK ORG WHT BLK GREEN TIE A B C 3-PIN M/P 150 TOWER BOOM 3 AUX 12VDC GND GND GND A B C 3-PIN M/P 150 SHROUD 10

11 Installation (cont) Speed Sensor Installation Installation Note: The harness provides local connection for the speed sensor. For speed sensor installations on implements, add 3-pin extension cables as required. Please Note: If you have purchased an Astro GPS Speed Sensor, a Vansco radar or other radar or GPS speed sensor, install the Astro, the Vansco or other radar as described in the instructions included with the unit. You may need an adapter cable to connect to radar or GPS Speed Sensor, see Appendix F. NOTE: If using a Micro-Trak Magnetic Speed Sensor kit, See Appendix A. Astro 5 GPS Speed Sensor Speed Sensor Options In addition to the standard Hall-effect magnetic speed sensor, the RoadMaster may be interfaced with a va ri ety of other speed sensing equipment. Several options are listed below. Astro series or other GPS Speed Sensor Interfaces The RoadMaster may also be used with most GPS speed sensors that output a pulsed signal, such as the Micro-Trak Astro 5, SkyTrak or Dickey-John GPS speed sensors. An adapter cable may be required. Vansco Radar Speed Sensor The Vansco radar speed sensor uses a microwave (radar) signal to deliver a reliable, accurate speed signal for electronic equipment. It features state-of-the-art electronic design/ manufacturing, rugged aluminum housing and complete testing and certification. Radar Interface The RoadMaster may also be interfaced with most popular radar ground speed sensors. An adapter cable is re quired for proper interface. SEE APPENDIX F FOR LIST OF ADAPTER CABLES FOR RADAR. Vansco Radar Speed Sensor Mounting and Plumbing Flowmeter The flowmeter must be installed in the main lane line after any strainers, return lines, or valves. Securely mount flowmeter (hardware not supplied) in a vertical position in an area away from intense vibration. DO NOT install flowmeter closer than 12 to the servo valve or the lane shutoff valves. The flowmeter is a bidirectional meter (Exception: Polmac s 1 1/2-3 ). Liquid can flow in either direction, but up is preferred, especially at rates below 5 GPM (19 lpm). Make connections using quick couplers or fittings without the use of reducers, elbows or sharp bends for a minimum of six inches (15 cm) either side of meter. See Illustration 4. Save plastic plugs (if supplied) to protect flowmeter during storage. The flowmeter may need periodic cleaning, so it should be easy to remove. Sprayer Line Hose Clamps* Hose Clamp* Illustration 4 Flowmeter Sensor (Green Body) Locknut L Bracket* * Not Supplied 11

12 Installation (cont) Installing Flow Sensor Cable With flowmeter in place, install the flow sensor cable. The flow sensor cable has a GREEN sensor body and mates with the main harness cable, having a GREEN cable tie near the 3-pin M/P connector. spin the jam nut on sensor threaded housing until it stops, insert threaded portion of sensor through bracket on flowmeter. Place second jam nut under bracket, hold and turn sensor into second nut. With sensor touching flowmeter body, tighten both jam nuts to lock sensor in place. Route the flow sensor cable to meet the extension cable from the main harness flow connector marked with GREEN tie. Align connectors and press firmly together until locking tab clicks into place. Secure cable with ties provided. See Illustration 5. Note: Sensors with GREEN bodies can be used for either or. Green Tie 5 Hall-effect Flow Sensor Cable with threaded sensor and male connector (P/N 13096) Flow Sensor Cable Connector Main Harness Flow Connector A B C C B A Illustration 5 Green tie Connect flow sensor cable to GREEN-tie console cable. NOTE: To maintain proper color codes, use the colored cable ties (GREEN) on the extension cable from the main harness flow connector. To Lane 1 To Lane 2 To Lane 3 Lane Valves Servo Installing Servo Valve On most installations, the servo valve installs in the main unrestricted spray line, between the flowmeter and the lane shut-off valves. It is not recommended to install the servo valve closer than 12 to the flowmeter. The servo valve has a flow direction decal on it. Make certain that the actual flow direction matches the decal on the servo valve. The servo valve connects directly to the main harness 3-pin W/P cable lead. If more length is required, use a 3-pin W/P extension cable of the appropriate length. Typical Installation Flowmeter From Pump Installing Optional Tank Level Switch A connection (See Wiring Diagram on Page 8) is provided for a Tank Empty switch. The switch must be a 2-wire, closed when tank is NOT empty and open when tank IS empty. Remove jumper and add 3-pin extension cables as required to reach the switch. 12 Installing External BLAST Switch An optional external Momentary On BLAST switch can be connected to the two quick-connect terminals provided on the harness (See Wiring Diagram on Page 8). The remote BLAST switch allows the operator to control the BLAST function from a switch mounted on an armrest or other convenient location. An optional switch box that includes the BLAST switch and RUN/HOLD switch is available from Micro-Trak Systems, Inc.

13 R o a d M a s t e r Console Functions The RoadMaster features a large, easy-to-read liquid crystal display, rotary dial and lighted panel for night use. Rotary Switch Position Functions KEYLOCK FUNCTION: When locked allows the user to view calibration values but prevents changes, allows Data Set 1 to be cleared but prevents clearing Data Sets 2 & 3 (Volume, Area, Distance, Average & Highest Velocity). tank alarm: Can be initiated by either the optional Tank Level Switch or the Tank Counter (If Tank Alarm is set in Special Calibration). remote blast switch - Optional: The Optional Remote Blast Switch can initiate the BLAST sequence in normal operation, the same as the console BLAST switch. audible alarm: Alarm will sound for Rate errors over 10%, Tank Level below set point or Tank Empty (from Float input). The alarm can be temporarily shutoff by setting rotary switch to MODE (Alarm Reset) and pressing the RESET button. Note: Setting ALARM ENABLE to OFF in Special Calibration will disable All Audible Alarms. VOLUME : Displays total gallons (liters) ) of liquid applied. May be reset. SEE NOTE VOLUME/MINUTE: Displays total gallons (liters) of liquid applied per minute. TANK LEVEL: Displays gallons (liters) of liquid remaining. If a FILL TANK SIZE has been set to a value in Calibration, pressing the + will make the Tank value jump to FILL TANK SIZE value. The value can be decreased but not increased above the FILL size. If the FILL TANK SIZE is set to Zero, Tank level can be adjusted to any value from 0 to 65,535 using the + or - (RESET) keys. Rate: Displays application rate. warning light: Indicates over or under application of plus or minus 10% from the Target Rate or if the tank is low or minimum flow active. Also lit when in. and Unlocked. Calibration Positions : Enter the calibration value assigned to your flowmeter (see flowmeter tag.) Min flow: Enter the minimum flow rate of the application system. Adjust Rate: Enter an amount of change for on-the-go adjustments to the target rate. TARGET : Enter the target application rate. Area : Keeps a running count of the total area worked. May be reset. SEE NOTE DISTANCE : Displays distance traveled. May be reset. SEE NOTE WIDTH : Enter the working width. MODE: Displays selected mode. User selects between Lane, Ag, Dust and Turf Modes of operation. Allows Audible Alarm to be RESET by Pressing the RESET button. : Displays ground speed in miles per hour (kilometers per hour) or Average & Highest velocity. May be reset. SEE NOTE Note: Volume, Area, DISTANCE & counters work in sets. If the VOLUME counter 1 is reset, it also resets AREA counter 1, DISTANCE counter 1 and Average & Highest Speed counter 1. This will be the same for resetting any counters in the set. Calibration Positions : Enter the speed calibration number in inches (cm) per pulse. MODE SELECT: Allows the user to change the MODE Select between modes of operation. Lane, Ag, Dust and Turf. TEST : Simulates ground speed for system checkout. Soft Key Functions AUTO MAN Key which changes operation from automatic control to manual. (If Manual Control is enabled, see page 21). Multi-functioned key: BLAST Used to enter & exit the calibration and special calibration modes. Used to initiate BLAST sequence in normal operations Overrides flowmeter input in case of an Emergency Stop. Toggles between and Distance traveled while fine tuning the factor or between and Volume when fine tuning the Flow Cal factor. See Appendices C & D. PROGRAM KEYS: In normal operating modes, used RESET to increase/decrease application rate. With Rotary Switch in the position, RESET key is used to display Average and Maximum Speed. In Volume, Area, Distance or Speed, the + key selects counter set. RESET: When in Hold and not in, clears the selected counter set when held for two sec onds. When rotary switch is in the MODE position, Resets Audible Alarm. When in, the + key increases and the - decreases the calibration value displayed. 13

14 Calibration Entering Calibration Values To enter or change any of the system s calibration values, you must enter calibration. NOTE: UNITS (English or Metric) must be set in Special Calibrate before any other IB or SPECIAL IB values. To enter calibration do the following: While in HOLD or with all nonzero Booms Off and no ground speed (stopped), holding the BLAST key for one(1) second will toggle IB on. The icon will turn on and any of the following eight Calibrate values can be viewed/ changed. If the Console is unlocked, the Warning LED will also turn on and any of the IB values can be adjusted. If the Console is locked, the Warning LED will not turn on and the IB (except TEST ) values can only be viewed and cannot be adjusted. TEST is active whether locked or unlocked. Once in calibration mode, you may change any one, all, or none of the values, in any order but it is recommended to set MODE first.* To select a calibration position, simply turn the rotary selector to the desired po si tion. Calibration positions are identified by the WHITE labeling on each side of the rotary selector. All values are entered and adjusted using the + and - but tons on the front panel. To exit Calibrate and save changes, hold the BLAST key again for 1 second. will disappear from the display and normal operations will start. If you decide not to save the changes made, power-down the console without pressing BLAST. Any changes will be restored to the original values when power is restored. *Test speed must be last. MIN ADJUST TARGET VOLUME VOLUME / MINUTE TANK LEVEL AUTO MAN BLAST Press to enter or exit calibration mode. HOLD RESET AREA DISTANCE MODE (ALARM RESET) WIDTH MODE SELECT TEST Press to increase or decrease values. Red warning light will be lit when in and unlocked. Illustration 6 Illustration 7 : This po si tion is used to cal i brate the flow me ter for ac cu rate liquid mea sure ment. Enter the factory calibration number stamped on the flowmeter tag (See Il lus tra tion 7) The Flow Cal number should not be changed during VOLUME operation because a change in the Flow Cal number will also change some counter values. MODEL NO. FM 750 GFN MFG BY MICRO-TRAK SYSTEMS, INC. MANKATO, MN USA SERIAL NO. GFN MS, INC. SA SERIAL NO NOTE: Your RoadMaster flowmeter has been tested at the factory and assigned a value to make it operate properly with the RoadMaster console. This number is stamped on the metal tag attached to the flowmeter. See Illustration 7. This is a starting point only. If your spray solution has a specific gravity or viscosity that is different than water, flowmeter calibration should be done for the specific solution (please refer to Fine-Tuning Flow me ter Calibration in Appendix D on page 36.) 14

15 Calibration (cont) Entering Calibration Values (cont) MIN : Displays the Minimum Volume/Minute from 0.0 to 6,553.5 assuming all nonzero Booms are turned on. The pur pose of this calibration setting is to prevent the system from applying below the recommended minimum flow rate for the nozzles. Enter the minimum flow rate in MIN VOLUME / MINUTE gallons per minute (li ters per minute) based on the nozzles being used, for the en tire boom width of the applicator. DO NOT enter the target flow of your spray application. For example: If the min i mum flow rate for the nozzle you are using is.22 GPM at their minimum recommended pres sure and your boom has 20 nozzles, enter 4.4 as the MIN value (.22 x 20 = 4.4). The system WILL NOT ap ply at a rate lower than this value when spraying in AUTO. The Warning LED will FLASH whenever the system is applying at Minimum Flow Rate but the Audible Alarm will not sound. This value should be checked/ changed for each different nozzle that you use. ADJUST : Displays the ADJUST or step size from 0.0 to in Ag, Lane or Turf mode and.000 to in Dust mode. In AUTO control with ADJUST selected, pressing TANK LEVEL + or - (RESET) will change the TARGET by the amount entered for ADJUST. This allows the operator to make changes to the TARGET quickly. To disable this feature, simply enter 0 for a val ue. TARGET : Selecting TARGET (in English) displays the desired application rate in Gallons/Lane Mile for LANE mode, Gallons/Acre for AG mode, Gallons/ Yard 2 for DUST mode and Gallons/Turf (1000 Feet 2 ) for TURF mode. Selecting TARGET (in Metric) displays the desired application rate in Liters/Lane Km for LANE mode, Liters/ TARGET Hectare for AG Mode and Liters/Meters 2 for DUST mode. TURF mode does not apply to Metric settings. This is the application rate that the console will lock onto when operating in AUTO. After the Auto Delay time and Start time have been completed the Warning LED will flash and Audible Alarm will sound if enabled whenever the actual application rate is more than 10% from TARGET. CAUTION: If spray lines are pressurized, nozzles may spray during WIDTH calibration (below). NOTE: When in Lane Mode, a Lane Mile/kilometer is defined as the area in a swath equal to the Center (Primary) Boom width, that is one (1) mile/km long. The user defines a Lane Mile/kilometer by changing the Center Boom width. For example, if the Center (Primary) Boom Width is set to 12 feet, and the Left and Right Booms are set to three feet, one mile traveled will result in an Area of 1.5 Lane Miles covered. WIDTH : Displays the Boom WIDTH from 0 to 65,535 inches or to meters for the Boom selected (Unused BOOMS must be set to zero). The total width (sum of all Boom widths) must not AREA WIDTH exceed 65,535 inches or meters. To adjust a particular boom, turn that Boom switch on and all others OFF. If no Booms are turned on it will display no boom to remind the user to turn a Boom on. Note: The system must be in RUN to display boom numbers. Repeat this procedure for each boom sec tion. Enter a value of "0" (.000) for any unused boom sec tions. Your working width per boom section will be the number of nozzles on the boom section times the nozzle spacing in inches (meters). For example, if you have 7 nozzles spaced at 20 inches, the working width of the boom section is 140 inches. NOTE: Most RoadMaster consoles are equipped with 3 Boom switches. In Lane Mode the CENTER BOOM switch is always the PRIMARY BOOM and is used to define the LANE WIDTH. Ag, Dust or Turf Modes can use any Boom switch. If the operator is only using ONE Boom it must be the Primary Boom. 15

16 Calibration (cont) Entering Calibration Values (cont) : This position is used to calibrate the speed sensor for ac cu rate speed and dis tance measurement. When this position is DISTANCE selected, the display will show the value along with "" on the display. In English units, the number is displayed in inches, in metric it is displayed in centimeters. The is factory-calibrated for use with an Astro GPS Speed Sensor. See the table below for numbers for other types of GPS speed sensor or radars. See Appendix B for procedure to calibrate if using a Magnetic Speed Sensor. See Appendix C for Fine-Tuning Speed Calibration. Radar or GPS Speed Sensor Calibration Radars English Metric Vansco Raven Magnavox Dickey-john (Radar Velocity Sensor II) GPS Speed English Metric Astro II & SkyTrak Dickey-john John Deere (In-Cab Speed Signal) Default Calibration Values Cal Factor English Metric Mode Lane Lane Speed Cal Flow Cal Min Flow 0.0 (Off) 0.0 (Off) Target Rate 20.0 Gal/Lane Mile 45.0 liters/ln km Adjust Rate 1.0 Gal/Lane Mile 1.0 liters/ln km Boom 1 Width 0 0 Boom 2 Width 96 in meters Boom 3 Width 0 0 MODE SELECT: MODE SELECT allows the user to change the MODE. Pressing the + or - (reset) will toggle between Lane, Ag, Dust and Turf (except in Metric) MODE and the display will show LAnE, Ag, dust and turf. MODE (ALARM RESET) MODE SELECT EXPLANATIONS OF LANE, AG, DUST AND TURF MODES: The differences are primarily the UNITS used for Area and Distance. LANE: Used for Highway Maintenance Applications where Area is accumulated in Units of Lane Miles (Lane Km). Distance is in Units of Miles (Km) and Application Rate is in amount of liquid per Lane Mile (Lane Km). AGricultural: Mainly used for roadside spraying, where Area is in acres (hectares), Distance is in feet (meters) and Application Rates are in Gallons/Acre (liters/meter 2 ). DUST CONTROL: Used for controlling air bourne particulates, where Area is in square yards (square meters), Distance is in yards (meters) and Application Rates are in Gallons/Yard 2 (liters/meter 2. TURF (English Only): Where Area is in 1000 square feet, Distance is in feet and Application Rates are in Gallons/1000 feet 2. NOTE: A Mode change CLEARS the counters if Calibration is exited correctly. If power to the console is turned off before exiting Calibration, the counters are NOT cleared. TEST : Enter the value to be used for simulating speed for performing Pre-application System checkout. The console will use this speed for simulating spraying operations. The test speed value is only used while in calibration mode. Once is exited, the Test Speed value is reset to zero. DO NOT ENTER A TEST UNTIL ALL OTHER VALUES ARE PROPERLY ADJUSTED. Please refer to Pre-application System Checkout for details. EXITING IBRATION: Upon completion of the calibration process, exit calibration. Basic calibration is now complete. Please refer to Pre-application System Checkout section to confirm overall system performance. 16

17 Calibration (cont) Calibration Log Sheet Serial No. Min Flow: Adjust Rate: Target Rate: Width Cal (Boom Width): left center right Speed Cal: Mode Sel: Test Speed: Comments: 17

18 Special Calibration Entering Calibration Values NOTE: UNITS (English or Metric) must be set in Special Calibrate before any other IB or SPECIAL IB values. There are three (3) pages of SPECIAL IB values, total of 18 used for Standard Drive, selected by the rotary switch and BLAST key. To enter Special Cal, put the system in HOLD, turn the console power OFF, press and hold the BLAST button while turning console ON. The console will display SPEC for 2 seconds to show that the console is in the Special Calibration mode. Release the BLAST button. Standard + - DC Special Calibrate If the Console is unlocked, the Warning LED will also turn on and any of the Special IB values can be adjusted. If the Console is locked, the Warning LED will not turn on and the Special IB values can only be viewed and cannot be adjusted. NOTE: Press and release the BLAST key to alternate between SPECIAL pages 1, 2, and 3 (Number icons indicate page). The desired Special Calibration Parameter(s) can then be accessed with the rotary switch. To exit Special Calibration, press and hold the BLAST button for 1 second. The console will save any changes and revert to normal operation. To exit without saving changes, simply turn the console power off without pressing BLAST. Special Cal Page 3 Manual Enable Special Cal Page 2 Minimum Alarm Speed Special Cal Page 1 Fill Tank Size VOLUME 1 AREA WIDTH Special Cal Page 1 Units (Eng/Metric) Special Cal Page 2 Set Year Special Cal Page 3 Start Time Tank Alarm Set Point MIN VOLUME / MINUTE DISTANCE Vehicle Number Set Month Auto Shutoff Blast Duration ADJUST TANK LEVEL MODE MODE (ALARM RESET) SELECT Valve Polarity Set Date Alarm Enable Auto Delay Time Blast Target Rate TARGET TEST Valve Speed Set Time AUTO MAN BLAST RESET Default Special Calibration Values Special Calibration Factor English Metric Tank Set Point Off Off Fill Tank Size Off Off Control Speed -1-1 Vehicle Number 1 1 Blast Target Rate 30 Gal/Lane Mile 65 liters/lane km Blast Duration 15 sec 15 sec Start Time 0 (Off) 0 (Off) Auto Delay Time 1 sec 1 sec Valve Polarity In-Line In-Line Auto Shut-Off Off Off Minimum Alarm Speed 0 MPH 0 kph Manual Control Enable On On Alarm Enable On On 18

19 Special Calibration (cont) Entering Calibration Values (cont) Page One FILL TANK SIZE: Selecting the VOLUME position on page one (1) allows the user to enter a FILL TANK SIZE VOLUME which can be toggled to OFF or 1 to using the + or - (reset) keys. The FILL TANK SIZE is in gallons in English or liters if in Metric Units. If a FILL TANK SIZE is specified, then pressing + while set to the TANK position (in Operation) will set the TANK value to FILL TANK SIZE for quick reloading. TANK ALARM SET POINT: Selecting the VOLUME/MINUTE position on page one (1) allows a TANK ALARM MIN VOLUME / SET POINT to be entered. MINUTE When Off no alarm sounds when the tank is emptied. If set to any other value, the Warning LED will flash, the alarm will sound and the display will alternate between FILL and normal when Tank value falls below the Set Point. BLAST DURATION: Selecting the TANK LEVEL position on page one (1) allows the user to enter the desired BLAST DURATION. It can be adjusted from 0 (Off) to 255 seconds. ADJUST TANK LEVEL BLAST TARGET : Selecting the position on page one (1) allows the user to enter the desired BLAST TARGET. The units and range are identical to the normal TARGET but BLAST TARGET is only used when the BLAST key is pressed. TARGET UNITS (English or Metric): NOTE: Changing UNITS will load defaults, so they should always be changed first and then all other IB and AREA WIDTH SPECIAL IB values may be set. Selecting the AREA position on page one (1) allows the user to change the UNITS and load defaults. Pressing the + or - (Reset) keys will toggle between English and Metric UNITS and the display will show En9 or nnet. NOTE: Trying to select Metric Units in Turf Mode will cause the Error message to be displayed. Defaults will not be loaded until the Rotary Selector is moved away from AREA or the Special Cal page is changed or Special Cal is exited normally. VEHICLE NUMBER: Selecting the DISTANCE position on page one (1) allows DISTANCE the user to change the VEHICLE NUMBER from 0 to 255 by using the + or - (Reset) keys. The VEHICLE NUMBER is downloaded with the Total and Configuration data through the serial port. Valve Polarity: Selecting MODE position on page one (1) allows the operator to install the flow control valve in either a By-Pass or MODE (ALARM RESET) MODE SELECT In-Line configuration. Pressing the + or - (reset) key will toggle the display between bypas and InLin. VALVE : Selecting the position on page one (1) allows VALVE to be changed, to adjust system response speed (if required). Pressing the + or - (Reset) keys will adjust the VALVE from -4 to 3. Normal setting is -1. NOTE: Use caution when adjusting the Valve Speed TEST setting. Higher values used with a fast valve may cause system instability (hunting, oscillations). 19

20 Special Calibration (cont) Entering Calibration Values (cont) Page Two ALARM MINIMUM : position on page two (2) allows adjustment of the ALARM MINIMUM. Pressing the + or - (Reset) keys will adjust the ALARM MINIMUM from 0.1 to 99.9 mph or kph. When the ground speed is below the ALARM MINIMUM, an Application Rate error will not generate an Audible Selecting the VOLUME VOLUME Alarm. Tank empty and Float alarms are not disabled. Setting the ALARM MINIMUM to Off will disable the function and allow audible warnings at any speed. This setting can be used to disable nuisance alarms while stopping and starting. START TIME: Selecting the VOLUME/MINUTE position on page two (2) allows the user to change the START TIME for the control valve. The START TIME can be MIN VOLUME / MINUTE adjusted from Off to seconds. The START TIME runs the Control Valve towards open for the amount of time (seconds) set, when a HOLD to RUN transition occurs. The control valve may be used to stop hydraulic flow and can be the cause of an undesirable delay for the Servo to return to normal operating flow. The START TIME cal value can be used to reduce this delay. AUTO SHUT OFF: Selecting the TANK LEVEL position on page two (2) allows the user to turn the AUTO SHUT OFF feature On or Off by using the + or - (Reset) keys. While in AUTO with the AUTO SHUT OFF turned off automatic control ADJUST TANK LEVEL will freeze the current flow when HOLD is pressed. With the AUTO SHUT OFF ON, the servo valve will run towards closed for 4 seconds each time HOLD is selected or ground speed is stopped. This is useful for stopping flow when using auger or belt delivery systems. SET YEAR: Selecting the AREA position on page two (2) allows the YEAR to be AREA WIDTH set from 07 to 99 for 2007 to 2099 using the + or - (Reset) keys. SET MONTH: Selecting the DISTANCE position on page two (2) allows the MONTH DISTANCE to be set from 01 to 12 (Jan to Dec) by using the + or - (Reset) keys. SET DATE: Selecting the MODE position on page two (2) allows the DATE to be set from 01 to 31 by using the + or - (Reset) keys. MODE (ALARM RESET) SET TIME: Selecting the position on page two (2) allows the user to change the TIME from 00:00 to 23:59 by using the + or - (Reset) keys. The LCD does not include a colon so a decimal point is used. MODE SELECT TEST AUTO DELAY TIME: Used to delay adjustment of the servo valve (in AUTO) until section or ON/Off valves have completely opened. Selecting the position on page two (2) allows the user to change the AUTO DELAY TIME by using the + or - (Reset) keys to vary the delay time from 0 (no delay) to 1, 2, 3 or 4 seconds. TARGET 20

21 Special Calibration (cont) Entering Calibration Values (cont) Page Three MANUAL ENABLE: Selecting the VOLUME position on page three (3) allows the user to turn the VOLUME MANUAL CONTROL ENABLE On or Off by using + or - (Reset) keys. Setting to Off disables Manual Control. Pressing the AUTO/MANUAL key will not toggle between Auto and manual when set to On. ALARM ENABLE: Selecting the position on page three (3) allows the user to turn the audible ALARM ENABLE On or Off by using the + or - (Reset) keys. Setting ALARM ENABLE to Off will disable all audible Alarms under all conditions. TARGET 21

22 Operation Console Switches & Buttons Make sure your system is properly calibrated before beginning to apply product. We also recommend completion of the Pre Application System Checkout described on page 25 prior to beginning any operations. The RoadMaster system can be operated in either Manual or Automatic mode. In manual mode, the application rates (See table below for different rates) are set using the + and - buttons; the application rate will vary depending on the vehicle speed. The manual mode is useful for system set up, spot applications, etc. To turn on the AUTO mode, press Auto/Man button so the Auto icon appears in upper right portion of display. In automatic mode, the system will control the flow rate to maintain the calibrated application rates (See page 23 for different rates) when the vehicle speed changes, or booms are turned on or off. To operate the system in automatic mode, simply turn on the desired number of booms, place the RUN/HOLD switch in the RUN position and drive. NOTE: In AUTO mode, the system will not turn the booms on until it has a speed signal. Use the Boom switches, the RUN/HOLD switch or remote RUN/HOLD sensor to Start or Stop application at any time. See the following sections for operation details. CONSOLE POWER/SYSTEM ON/OFF When the RoadMaster Console is turned on, except when starting SPECIAL IB, the data display will show the Number of Hours it has operated for one (1) second, the Software Part Number (45022) and Software Revision for 1.5 seconds each. Then it will display Std for 1.5 seconds showing that this is a Standard DC Servo Drive Console. DISPLAY During normal operation, the console will display information selected by the rotary switch position. Typically the rotary switch will be set on, as shown in Illustration 8. With selected, the console will display the Application Rate based on the Mode and Units selected. run/hold switch The Run/Hold is the master switch for turning all (active) booms on and off. This function can be done either manually with the included Run/Hold switch, or automatically, using the optional Run/Hold sensor kit. AUTO/MAN button This button will switch the control status of the system from fully automatic to manual control. Each press of the button will change the status. The display will show the AUTO icon when automatic control mode is active and the MAN icon when manual control mode is active. NOTE: IF IN AUTO MODE AND NO SIGNAL IS PRESENT, SYSTEM WILL SHUT OFF THE BOOMS AUTOMATILY. MIN ADJUST TARGET VOLUME VOLUME / MINUTE TANK LEVEL AUTO MAN BLAST 1 RESET AUTO AREA DISTANCE Illustration 8 WIDTH MODE MODE (ALARM RESET) SELECT TEST BLAST button The BLAST function is intended for spot applications (bridge decks, intersections) at a higher rate. The BLAST calibration functions include BLAST TARGET and BLAST DURATION. When the user presses the BLAST switch in Auto, the system will display BLASt and output the preset rate for a preset period. The period starts after the BLAST switch is released. If the BLAST switch is pressed again during the reset period, BLAST will be cancelled. When the BLAST is complete, the system returns to normal operations. BLAST will NOT function in Manual mode or if the system is in HOLD or stopped. + and - buttons During normal operation, when automatic AUTO control mode is active and the rotary dial is set to, each press of the + or - buttons will increase or decrease the target application rate by the amount of the calibrated Adjust Rate. During normal operation, when manual MAN control mode is active and the Run/Hold switch is in the RUN position, and Rotary dial is set to or VOLUME/MINUTE, pressing the + or - buttons will increase or decrease the application rate. During normal operation, when either automatic or manual mode is active, the Run/Hold switch is in the HOLD position and the rotary switch is turned to VOLUME/MINUTE, pressing the + or - button will increase or decrease the flow rate without having the boom valves turned on. This can be useful for system pressure checking. 22

23 Operation (cont) Console Switches & Buttons (cont) boom SWITCHES The system monitors the status of the boom switches to determine whether they are ON or OFF. The console accumulates area based on the calibrated boom widths. When an individual boom is turned OFF, the respective width is subtracted from the total width to accumulate area based on the new active application width. If the rotary switch is in the position, the numbers 1, 2, 3, 4 or 5 on the display will light when their respective boom is ON. NOTE: Most RoadMaster consoles are equipped with 3 Boom switches. In Lane Mode the CENTER BOOM switch is always the PRIMARY BOOM and is used to define the LANE WIDTH. Ag, Dust or Turf Modes can use any Boom switch. If the operator is only using ONE Boom it must be the Primary Boom. 3 - Boom Configuration Boom 2 is Primary { B O O M S Warning device The console is equipped with a RED warning light. The light will automatically turn on and flash when the actual application is plus or minus 10 percent of the calibrated target rate, or if the TANK alarm feature is activated and the tank is below the set point (display will also flash FILL message). If the light stays on while in AUTO, refer to the troubleshooting section of this manual. The RED warning light will also be illuminated when calibration mode is active on the console. AUDIBLE ALARM The Audible Alarm is activated for the following conditions: 1. The calculated Tank Level is below minimum level (TANK ALARM SET POINT) 2. Float switch is continuously active for 15 seconds or more. 3. The application Rate Error is greater than 10% for 3 seconds (continuously) after the Auto Delay and Start Up time have completed and the console is in AUTO, and the Ground Speed is above the Alarm Minimum Speed. ON OFF EMERGENCY STOP When in AUTO and in RUN with one or more Booms on and the Speed is greater than zero, if the Flow signal ever stops, the servo will run to fully open. If Flow remains stopped for 5 seconds or more, it will automatically reduce the flow to a minimum (run Servo closed for 4 seconds). EStOP will then display to notify the user of the Emergency Stop. The flow remains off (or reduced) and AUTO control will remain disabled until the system goes into HOLD, power is cycled or IB is entered. The Emergency Stop feature helps protect against chemical spills or over-application if the Flow signal is lost. NOTE: Volume, Area, DISTANCE & counters work in sets, if the VOLUME counter 1 is reset, it also resets AREA counter 1, DISTANCE counter 1 and counter 1. This will be the same for resetting any counters in the set. Do Not use the - button to select counters because the button will clear them. (See Resetting System Counters on page 25). The active set of counters may be reset to zero independent of other sets of system counters. SERIAL PORT The DB-9 connector on the back of the console provides access for Serial Communication to/from the console. The Serial Configuration is RS-232, 9600 baud, in 8-N-1 half-duplex format. Data is sent and received in comma-delimited ASCII format. An external device (GPS/Mapping/AVL System) can change the application rate on-the-go and also receives and records data from the RoadMaster. See Appendix H and I for data lists available. Rotary Switch Positions rotary switch During normal operation, you can view any one of eight monitored functions by turning the rotary switch to the appropriate position. The functions that are active during normal operation are the BLUE boxes. Calibration positions are identified by the WHITE labeling on each side of the rotary selector (Please refer to Calibration section for details). VOLUME Displays the total gallons (liters) applied since the active counter was last reset to zero based on the UNITS selected. Number Icons indicate which set of counters is being displayed. Press the + button to select other counter sets. VOLUME/MINUTE Displays the gallons (liters) per minute being applied. TANK LEVEL Displays amount remaining in the tank. When the tank is refilled, and the tank volume has been entered in Calibration, the TANK LEVEL amount can be reset to a full tank by simply pressing the + button for 1 second while the rotary switch is in the TANK level position. The amount in the tank can be decreased by using the - button but cannot be increased above the FILL size. If no FILL TANK SIZE is specified, the + or - (Reset) keys can be used to adjust Tank to any value. The Tank value cannot be changed while in IB or SPECIAL IB mode except while TEST is set. 23

24 Operation (cont) Console Switches & Buttons (cont) rate Displays the Application Rate based on the selected MODE (See Table below). MIN ADJUST VOLUME VOLUME / MINUTE TARGET TANK LEVEL AUTO MAN BLAST AUTO 1 RESET AREA WIDTH DISTANCE MODE (ALARM RESET) TEST Mode English Metric Lane Gallons/Lane Mile liters/lane km Ag Gallons/Acre liters/hectares Dust Gallons/Yards 2 liters/meters 2 MODE SELECT MODE Displays Current Mode (Lane, Ag, Dust and Turf). Note: Turf mode is not available in Metric Units. speed Displays the ground speed in miles (kilometers) per hour. When the operator selects, the Current Velocity will be computed and displayed in 0.1 increments from 0 to mph or kph. In the position, the Number Icons indicate which data set is selected and changes each time the + button is pressed. If the user presses the - (RESET) key the display will change from Current Velocity to display the Average Velocity (for the selected data set) for 2 seconds. The display will then display the Highest Velocity for 2 seconds and return to display Current Velocity. The Left most digit will display A for Average and H for Highest when the average and highest speed is being displayed. Speed will continue to operate while in HOLD or all nonzero Booms are off, if a speed signal is still present. Average and Highest will NOT be changed while in HOLD. The Illustration to the right shows the Speed in Data Set 1 and the - (RESET) key has been pressed to show the Highest (H) speed. Turf Gallons/Turf n/a Area Displays the area covered since the counter was last reset to zero based on the MODE selected. The area counters do not accumulate area when the console is in HOLD or if all booms are turned OFF. Number Icons indicate which set of counters is being displayed. Press the + button to select other counter sets. AREA is displayed in the following units based on UNITS and MODE MIN VOLUME VOLUME / MINUTE 1 AUTO AREA DISTANCE WIDTH Mode English Metric Lane Lane Miles Lane km ADJUST TANK LEVEL MODE (ALARM RESET) MODE SELECT Ag Acres hectares Dust Yards 2 meters 2 TARGET TEST Turf 1000 Feet 2 (Turf) n/a distance: Displays the distance driven since the counter was last reset to zero based on the MODE Selected. This counter does not accumulate when the console is in HOLD or all Booms are off. Number Icons indicate which set of counters is being displayed. Press the + button to select other counter sets. AUTO MAN BLAST RESET DISTANCE traveled is displayed in the following units based on UNITS and MODE Mode English Metric Lane Miles Kilometers Ag Feet Meters Dust Yards Meters Turf Feet n/a 24

25 Operation (cont) Resetting System Counters The VOLUME, AREA, DISTANCE & data counters maintain a running count during operation regardless of the position of the rotary switch. When any of these counters reach their maximum capacity, or when you want to start a new count, the value may be reset to zero by performing the following routine. Counter sets may be reset independently of each other. NOTE: If the console is locked, only Data Set 1 can be cleared. 1. Turn the booms OFF or put the system in HOLD. Display indicates that counter set #1 is selected MIN ADJUST TARGET VOLUME VOLUME / MINUTE TANK LEVEL HOLD 1 AREA DISTANCE WIDTH MODE MODE (ALARM RESET) SELECT TEST Turn the rotary switch to Volume, Area or Distance. There are three independent VOLUME counters, paired with three AREA counters, paired with three DISTANCE counters and with three Values (Average and Highest velocity). The active set of counters is indicated by the small numbers in the lower right area of the display (1, 2, or 3) when the rotary switch is in the VOLUME, AREA or DISTANCE position. Select the set of counters you want to RESET by pressing the + button. The small number will increment each time the + button is pressed (from 1 to 3, then rolls back to 1). DO NOT attempt to select the counter number by using the - button, because that will clear the active set of counters if held for 2 seconds. If the - button is accidentally pressed, the console will display CLEAr to alert the user that the counters will be cleared. If the user continues to hold the - button for 2 seconds CLEAr will disappear and be replaced by 0.0, indicating that the selected set of counters has been cleared. AUTO MAN BLAST RESET Display indicates that counter set #2 is selected MIN ADJUST TARGET VOLUME VOLUME / MINUTE TANK LEVEL AUTO MAN BLAST RESET HOLD 2 AREA DISTANCE WIDTH MODE MODE (ALARM RESET) SELECT TEST HOLD Display indicates that counter set #3 is selected VOLUME AREA WIDTH HOLD 3 MIN VOLUME / MINUTE DISTANCE VOLUME AREA WIDTH ADJUST TANK LEVEL MODE (ALARM RESET) MODE SELECT MIN VOLUME / MINUTE DISTANCE TARGET TEST ADJUST TARGET TANK LEVEL MODE MODE (ALARM RESET) SELECT TEST AUTO MAN BLAST RESET AUTO MAN BLAST RESET 25

26 Operation (cont) Pre-Application Sys tem Checkout Before beginning actual application, perform the following Pre-field procedure to ensure that your valve settings, nozzle selection and desired speed range will allow the RoadMaster to provide the required application control. By performing all of the steps listed below, you set up your system to allow the RoadMaster to perform at optimum level. Fill your application tank with clean water. DO NOT use chemicals until the entire sys tem is completely checked out and operating properly. NOTE: Pre-field System Checkout is a procedure performed while the console is in the mode. During the procedure and on the display will be flashing. 1. Start vehicle and bring the engine up to normal operating RPM. 2. Enter MAXIMUM application TEST into con sole. With console in HOLD, enter calibration mode. Push and hold (BLAST) button. will appear on display and red light will be on if unlocked. Turn rotary switch to TEST position. Use + or - button to enter maximum application speed. Do not exit cal i bra tion mode. will flash indicating TEST mode. 3. Select manual MAN control mode, turn all active boom switches to ON position and put Run/Hold switch in RUN position. NOTE: even if no boom valves are being used, the primary boom should have the proper width entered, and it is used to turn the system on. 4. Turn Rotary switch to position and hold + button to increase the to maximum. The display should now read more than the maximum desired Application Rate. CAN T GET THERE? If you can t get to the desired ap pli ca tion rate, you may need a different pump, or mod i fi ca tions to your plumbing configuration. Please refer to Trou ble shoot ing Plumbing. Care and Maintenance of your RoadMaster Console Store the console in a cool, dry location if it will not be used for an extended period of time, such as during the off-season. As with any electronic equipment, use care in cleaning so that water or other liquids do not enter the case. Thoroughly flush flowmeter with clean water, install plastic shipping plugs and keep from freezing. Precautions MIN ADJUST TARGET VOLUME VOLUME / MINUTE TANK LEVEL AUTO MAN BLAST HOLD RESET AREA Illustration 10 DISTANCE MODE (ALARM RESET) WIDTH MODE SELECT TEST Now is a good time to confirm that, VOLUME/MINUTE, MPH, WIDTH and PSI all coincide with the nozzle man u fac turer s charts. PSI may be slightly higher than indicated by the charts due to pressure drop across the boom valves, nozzle diaphragm check valves, nozzle screens, etc. Enter MINIMUM application TEST into con sole. Turn rotary switch to TEST position. Use the + or - button to enter minimum application speed. Do not exit calibration mode. (Remember, the minimum application speed is not normally less than half of the maximum application speed.) Put Run/Hold switch in RUN position (make certain system is in Manual mode), turn rotary switch to position and hold - button to reduce the rate to minimum. The display should now read less than the minimum desired application rate. CAN T GET THERE? If holding the - button does not get the application rate to go below the minimum desired ap pli ca tion rate, please refer to Troubleshooting Plumbing. Do not expose the flowmeter to liquid temperatures exceeding 130 degrees F (55 degrees C). Some chemicals may damage the noryl turbine or the body of the flowmeter. If you are in doubt, contact the chemical manufacturer. 26

27 Troubleshooting Messages/Warnings M Average Speed (for selected Data Set) is being displayed for 2 seconds. M Indicates memory fault. Cycling power will not clear the bad message, it can only cleared by entering Calibration or Special Calibration modes, checking and/or changing settings and exiting to save settings. BLAST is active (Blast key was pressed). The message alerts the user that the currently selected counter will be cleared if the reset button is held for 2 seconds. Also serves as a reminder to use + button to select counters. Had an Emergency Stop. Check flowmeter. Verify there is liquid flow and the tank is not empty. Can be overridden to continue application without a flowmeter by pressing BLAST MAX PWM is correctly calibrated. Trying to select Metric Units in Turf Mode or Turf Mode in Metric Units. Rotary switch in any position, FILL will flash if tank level is equal to or less than Tank Set Point or Float Switch detects empty Tank. Fill TANK. If using TANK counter and Tank Alarm Set Point reset TANK counter by setting the rotary switch at the TANK position and pressing the + button for one second. Check to make sure TANK ALARM SET POINT is properly calibrated. Highest Speed (for selected Data Set) is being displayed for 2 seconds. In Lane Mode when a Boom is selected for Width Cal a letter will display for 1 second that identifies the selected Boom. After 1 second the displayed BOOM letters clear and the Boom Width is displayed. Low Power. Check all power and ground connections. Will flash in display if rotary switch is in Width position, system is in Cal mode and no booms are turned on. Make sure system is in run and a boom switch is turned on, also check Run/Hold switch or sensor and connections. Will flash in display if rotary switch is in position and should have flow (In Run, some booms on, speed greater than 0) but no flow is detected. Check flowmeter and flow harness connections per Troubleshooting section. Will flash in display if rotary switch is in position and there is no Speed signal regardless of all other conditions. Check speed sensor and connections per Troubleshooting section. Counters (DISTANCE or AREA or VOLUME) have overflowed their maximum. RESET (see page 25) to clear counters and resume counting. "Special" Calibration mode is active. Appears when entering Special Calibration mode (hold AUTO/MAN and buttons while turning console on). An unused SPECIAL IB or LIVE IB position. Warn LED flashes when the Rate error is over 10% or Volume/Minute is below the Minimum, or Tank is less than Tank Set Point. It is on steady when in mode or SPECIAL mode or Test Speed if console is unlocked. Audible Alarm Alarm will sound if Alarm Enable is ON and either the Tank Level is below minimum or the Optional Tank Level Switch is active, or if Application Rate error rate is greater than 10% and the console is in Auto with adequate ground speed. 27

28 Troubleshooting (cont) General All RoadMaster consoles, flowmeters and harnesses are tested prior to packaging, so unless there has been damage in shipment you can be confident that everything will be operational when you receive it. However, if you do encounter a problem that appears to be related to equipment failure, PLEASE DO NOT OPEN THE CONSOLE. Your system is protected by a warranty, and Micro-Trak Systems, Inc. will gladly correct any defect. Many problems are the result of mistakes in installation or operation. Before returning any parts for service, carefully check your installation and review the operating instructions. For easy-to-follow guidelines, refer to the Troubleshooting Section which follows. Console appears dead Using your test light, check for 12 volts at the power source. Trace cable toward battery look ing for breaks. Also check any fuses or circuit break ers that supply pow er to the console. Then check for damaged power cable or reversed terminals. (Console requires 12 volts for proper operation). Speed is always zero or erratic Check for properly calibrated number. Review speed sensor installation. If using a Magnetic Speed Sensor, check for proper mounting, alignment and spacing of speed sensor in relationship to magnet assembly. Make sure magnet polarities are alternated. Also check cable for breaks or incomplete connection. NOTE: For more suggestions on solutions to speed problems, see console input section and Troubleshooting Sensor section on next page. Area count is inaccurate Implement width or Speed Calibration was measured incorrectly or programmed incorrectly. Go back through the original procedures, make changes, and test for area count again. Verify accuracy with formula: Turf = Distance x Width in feet/1000 Yard 2 = Distance x Width in yards Acres = Distance x Width in feet/43560 Hectares = Distance x Width in meters/10,000 Meters 2 = Distance x Width in meters Distance count is inaccurate Speed Calibration was incorrectly measured or entered. Review calibration, readjust and test. See Appendix C. No readout of gallons (liters), or gallons (liters) per minute Check to see that the pump and equipment are operating properly. If liquid is moving through the line, check the flow sensor to be sure it is screwed all the way into the flowmeter. Check to see that a number has been entered. Also check cable for breaks or incomplete connection. (See Console Input Section). If the flowmeter is new or has not been used for a long period of time, the turbine may be sticky. Flushing the system out with water should make the turbine spin freely. Flow rate may be too low to register a reading, or foreign material may be lodged in the flowmeter. Shaking the Flowmeter end to end should pro duce a rattling sound (shaft end play). Blowing in the meter from either end should spin the turbine freely. See Flow me ter Assembly; Appendix E, for details. Total liquid used is inaccurate This may result from an incorrectly-entered value. Check the number stamped on the flowmeter tag, and be sure this is entered in the console s position. If the meter has been used for some time, wear may have changed the Flow Cal value. Check the mounting position of the flowmeter. With lower flow rates, the meter should be mounted vertically with flow going up. Another cause may be inaccurate sprayer tank markings. Electrical interference Erratic operation of the system may be the result of electrical interference from ignition wires or inductive loads (electrical clutch, fan, solenoid, etc.). Always try to route wires as far away from suspect areas as possible. If problems occur, you may need to relocate the console and/or wiring harness, or install a noise suppressor and/or spark plugs. Displayed measurements do not make sense The console may be in the incorrect measurement units (English or Metric) or Application mode. NOTE: Changing UNITS will load defaults, so they should always be changed first and then all other IB and SPECIAL IB values may be set. MODE SELECT in IB allows the user to change the MODE. Pressing the + or - (Reset) will toggle between Lane, Ag, Dust and Turf (except in Metric) MODE and the display will show LAnE, Ag, dust and turf. Display reads OFL DISTANCE, TOTAL AREA, and TOTAL will read OFL when they have exceeded their maximum count. Reset to zero to resume counting. 28

29 Troubleshooting (cont) Checking Individual Components Harness The harness can be checked using an ohm me ter or continuity tester. The main wiring diagram shows the pin-out of all connectors. See page 8 for wiring diagram. MAGNETIC HALL-EFFECT AND SENSORS Caution: Improper connection or voltage could damage the Hall-effect sensor. This par tic ular type of Hall-effect sen sor re quires al ter nat ing magnetic po lar i ties in or der to switch. This means that the north pole of a mag net will open the Hall effect and the south pole of a magnet will close the Hall effect. SENSOR Ground pin C (black) and connect clean 12 volts to pin B (white) of the Hall-effect sensor cable. Con nect the positive lead (red) of an ohmmeter or con ti nu ity tester to pin A (red) and the negative lead (black) of the ohmmeter or continuity tester to pin C of the Hall-effect sensor cable. SENSOR Ground pin B and connect clean 12 volts to pin A of the flow sensor cable. Con nect the positive lead (red) of an ohmmeter or con ti nu ity tester to pin C (red) and the negative lead (black) of the ohmmeter or continuity tester to pin B of the flow sensor cable. Holding the tip of the sensor up to the north pole of a magnet should result in a very high re sis tance (in fi nite), while holding the tip of the sensor up to the south pole of a magnet should result in a very low resistance (near zero). ASTRO II AND ASTRO 5 GPS Carefully check your installation and operating instructions. The following are tips for troubleshooting: 1. Make sure that power (12 VDC is available to the sensor and complete the Speed Input tests. (See Console Input section). 2. Check to make sure that the GPS module is securely mounted. 3. Check for any damage to the 10 foot receiver cable. 4. If system passes all above tests, the Astro may be defective. VANSCO RADAR SENSOR Carefully check your installation and operating instructions. The following are tips for troubleshooting: 1. Make sure that power (12 VDC is available to the sensor and complete the Speed Input tests. (See Console Input section). 2. If system passes all above tests, the radar may be Illustration 11 defective. C B A electric boom valves If 12 volts and signal are present, but valves will not actuate, consult valve manufacturer s troubleshooting instructions. plumbing Proper plumbing is a very important factor in obtaining optimal performance from your RoadMaster system. In addition, make certain that you have selected and installed the correct spray tips for the application, speed and spray rate that you intend to maintain. Don t forget the obvious Three-Pin Connector such as leaky fittings and hoses, pinched hoses and plugged or worn nozzles. 29 CONSOLE INPUTS If there is no response from any of the following tests, refer to the main wiring diagram to locate the next connector in line to ward the con sole and repeat the test at that con nec tor. If there is a response at that connector, the problem may be in the cable between the two connectors (or the con nec tors themselves). INPUT Turn rotary switch to po si tion and dis con nect the speed sensor (yel low tie) from the main harness. Check for 12 volts between pins B (red) and C (yellow) of the main harness speed cable (yellow tie). Using a clip lead or other jumper wire (such as a paper clip bent in a U ), several times rap id ly short to geth er pins A (orange) and C (yellow) of the 3-pin connector (See Illustration 11). The console should respond with some speed read ing. INPUT Turn rotary switch to VOLUME/MINUTE (not ) and disconnect the flow sen sor (green tie) from the main harness. Check for 12 volts be tween pins A (violet) and B (gray) of the main harness flow cable (green tie). Using a clip lead or other jumper wire (pa per clip bent in a U ), several times rapidly short together pins B (gray) and C (blue) of the 3-pin connector (See Il lus tra tion 11). The con sole should re spond with some Volume/Minute reading. TANK SWITCH INPUT First Verify that ALARM ENABLE is ON. (See Special Calibration page 21). With ALARM ENABLE turned ON, if the Tank Switch is opened, the Audible Alarm should turn on after a 15 second delay. If the switch is closed, the alarm will turn off. Verify by disconnecting the switch and shorting pins A and C on the cable connector. RUN/HOLD INPUT If using P/N (Run/Hold Switch Kit) or other switch, disconnect the cable from the switch and the HOLD Icon will NOT be displayed. Short between pins A and C and the HOLD Icon should turn on; if not, the console input is bad, otherwise either the switch or extension cable is bad. If using a Hall-Effect magnet Run/Hold sensor, first check for 12V between B and C, then proceed per above.

30 Plumbing Guidelines General In order for your sprayer to function properly, it must be correctly plumbed. A word about pressure drops: All hose, valves and fittings (especially elbows) cause undesirable pressure losses. Keep hoses as large as practical. Don t use longer hoses than necessary. Avoid bends whenever possible. Use as few fittings as possible. Use full port valves or the next larger size valve. Long hoses should be supported to avoid sagging and kinking. Many spray tip manufacturers have charts showing pressure drop for various fittings and hose sizes. Now let s break the system into three sections and cover each one separately. The three sections are the pump inlet line, the flowmeter (boom) line, and the pump itself. Pump Inlet The hose connecting the tank to the pump should be at least as large as the pump inlet port. The valve in this line is for complete tank shut-off only and should always be fully open during operation. If this hose is too small or the valve is partially closed, you may not be able to reach your high end goals and pump damage could occur. Flowmeter The line feeding the flowmeter and the boom shut-off valves should be at least as large as the flowmeter. The size of lines going from the shut-off valves to each boom section depends on the flow rate of each boom. Pump The pump must have enough capacity to satisfy the flowmeter sections of the plumbing. To determine if your pump is large enough you must add up the volume per minute of all active sections. 30

31 Appendices 31

32 Appendix A Optional Speed Sensor Mounting Installation Magnets Please read the following information about magnet spacing and polarity. The number of magnets that must be used depends on the size of your tire and where you mount the sensor. On wheels the general rule of thumb is one magnet for each wheel bolt (minimum of two, and always an even number). For drive shafts, two magnets are usually adequate. Some installations may require that more than two magnets be installed. To determine the number of magnets required, measure the distance traveled of one revolution of the sensor equipped wheel in inches (centimeters). See the following tables to find the minimum number of magnets required (always an even number) - The magnets provided by Micro-Trak are marked with a punched dashed line on the SOUTH pole side of the magnet. See Illustration 12A. Always use an even number of magnets, and always alternate the polarities of the magnets as you go around the wheel hub or drive shaft. To install, mount the first magnet with the SOUTH pole side (dashed line) facing toward the hub or shaft. Mount the second magnet with the NORTH pole side facing toward the hub or shaft. See Illustration 12B. For proper operation, the magnets must be evenly spaced around the wheel or drive shaft. The magnets must be at least 1 apart. See Illustration 12C. NOTE: Magnets may be attached mechanically or adhered with epoxy or other high quality adhesive. When using adhesive, thoroughly clean the area of dirt and oil. English or Turf (inches) Wheel Circumference Number of Magnets Metric (cm) Wheel Circumference Number of Magnets Locations where the magnetic sensor may be installed: 1. Non-driven wheel on the vehicle. This is less susceptible to errors resulting from wheel slip. 2. Vehicle drive shaft. This type of mounting is recommended for trucks, four-wheel drive tractors or other equipment that has poor or no access to a non-driven wheel. See Appendix B for magnetic speed sensor installation details for various types of wheels or drive shaft. Locate the following parts: Speed sensor cable (Green body) Mounting L bracket Magnets Cable ties Illustration 12B South North 5 North 6 Illustration 12C South 2 South S N North 1 Minimum Illustration 12A Test magnet should alternately attract and repel. 32

33 Appendix A (cont) Attaching the Speed Sensor The magnets are attached to a wheel hub or drive shaft and the speed sensor is mounted directly over the magnet. When the wheel or drive shaft begins turning, a speed impulse is sent to the RoadMaster console every time a magnet passes by the tip of the speed sensor. For the speed sensor to operate properly, the spacing between the magnets and the tip of the sensor must always remain constant. Before permanently mounting any parts, be sure that the location you have selected will meet the requirements shown in Illustration 13. NOTE: Observe magnet polarities (see previous section). 45 max Sensor assembly must not be mounted more than 45 from perpendicular Sensor (Green body) ¼ to ½ air gap Bracket must be rigidly mounted 3/8 nuts Illustration 13 Magnet Connecting the Speed Sensor Cable The speed sensor cable has a green sensor body and mates with the 3-pin connector which is marked with a yellow cable tie. The speed sensor and the flow sensor must be connected to the proper harness connector. The speed sensor always connects to the 3-pin M/P connector with the yellow tie and flow sensor always connects to the 3-pin M/P connector with the green tie. See the RoadMaster Wiring Diagram on page 8. The optional Run/Hold sensor, also uses the same type of connector as the speed and flow sensors. However, the Run/ Hold sensor has a gray tie near the 3-pin connector, the sensor body is black, and it always connects to the main harness lead with the gray tie. See the RoadMaster Wiring Diagram on page 8. Sensor identification Chart SENSOR SENSOR BODY COLOR MAIN HARNESS TIE COLOR Speed Green Yellow Flow Green Green Run/Hold Black Gray 33

34 Appendix A (cont) Optional Speed Sensor Mounting on Drive Shaft NOTE: This is an optional method generally used on pickups or custom vehicles. It may also be nec es sary on any other vehicles where ac cess to the wheels is lim it ed. This in stal la tion requires a spe cial calibration procedure, see page 16. Determine the best location for the magnets on drive shaft according to which is the most practical spot to attach sensor mounting bracket. This position should be no more than 12 (.30 meters) behind the front U-joint. For best results, mount L bracket to transmission and mount magnets on drive shaft as close to transmission as pos si ble. This will en sure prop er alignment if drive train shifts under heavy loading. Two magnets are required for proper Hall-effect speed sensor operation. Position them exactly opposite each other (180 de grees apart). The polarity (north and south poles) detect ed by the Hall-effect speed sen sor must alternate as the shaft is turned. The magnets provided by Micro-Trak are marked with a punched dashed line on the SOUTH pole side of the magnet. Sensor Body (Green) Attach magnets onto drive shaft, one NORTH pole side out and the other SOUTH (dashed) pole side out, by wrapping ca ble tie around shaft and magnets. Position each mag net so that its longest dimension moves in the di rec tion of rotation. Pull cable tie tight and trim off excess. An adjust able, non-magnetic (stain less steel) band clamp may also be substituted. Attach sensor bracket to vehicle transmission with bolts, lock washers and nuts provided. See Illustration below. (Use self-tapping screws if bolts are not prac tical.) Use either the short or long end of the brack et as a base. (Allow enough room be tween the bracket and the magnets so that when prop erly spaced, the tip of the sensor will extend 1/4 [7mm] or more be yond the lock ing nut.) Turn one locking nut onto threaded sensor and in sert sensor into large hole selected on mount ing brack et. Turn on remaining locking nut. Set sensor to proper distance from magnets (1/4 to 1/2, or 6mm to 13mm). When distance is set, tight en nuts to lock sensor in place. Secure sensor cable to frame with cable ties. Place first tie as close to sensor assembly as possible. fasten Sensor Bracket with existing Transmission Bolts or rigidly Attach with clamps. ¼ to ½ (6mm to 13mm) Spacing Transmission/ Transfer case drive Shaft Drive Shaft Speed Sensor Calibration Because of the difference in wheel-to-drive shaft ra tios, it is difficult to determine a calibration value for installation on a drive shaft by measuring a wheel. You must start with an estimated calibration value (10-15) and then fine-tune the cal i bra tion. Go to Appendix C for Fine-Tuning Instructions. Magnets Positioned 180 Apart 34

35 Appendix B Calibrating if Using a Magnetic Speed Sensor Determining the For the console to calculate the correct speed and measure distance accurately, the circumference of the sensor-equipped wheel must be entered. Determine the circumference of the sensor-mounted wheel to the nearest tenth of an inch (tenth of a centimeter) with the fol low ing method: METHOD Mark the tire with a piece of chalk and mea sure the distance traveled on the ground for one com plete rev o lu tion. See Illustration 14. For improved accuracy, it is recommended that you perform this function in field conditions, measure several revolutions, and take the average. Divide the measured revolution by the number of magnets installed to get your starting calibration value. Once calibration of the system is complete, this number should be fine-tuned for optimum accuracy. For fine-tuning the value, see Appendix C on page 36. Illustration 14 To determine, measure the distance of one complete wheel revolution and divide by the number of magnets installed. 35

36 Appendix C Fine Tuning Speed/Distance Calibration Val ue This procedure is used to verify the Speed/Distance calibration. In order to achieve accurate measurements, each step in this fine tuning procedure should be performed as precisely as possible. Preparation Once the system is fully installed and calibrated, se lect a straight tract of ground that is similar to your ac tu al application conditions and as level as pos si ble. NOTE: Us ing a course with a different ground sur face, such as a hard-surface road, will re sult in dif fer ent read ings than exact application conditions. Measure an appropriate distance for Application Mode. AG and TURF are measured in feet (meters). Dust is measured in yards (meters) and Lane is measured in miles (km). Clear ly mark the beginning and end points with flags or some thing highly visible to the operator. Procedure 1. With the console turned ON, place the Run/Hold switch in the HOLD position. The HOLD icon will be displayed. Select the Counter (1-3) you want to use. Be sure the display shows 0. If not, reset the distance counter by pressing and holding RESET until the display returns to 0 (approximately two seconds). The word CLEAr will be displayed when reset is pressed. Make sure pump is off. Turn on Boom switches. 2. You are now ready to drive the measured course. Pick a location on the vehicle to use as a marker for starting and stopping the distance counting function (door handle, mirror, step, etc.). You should begin driving the course well ahead of the starting flag and drive past the ending flag, using the Run/Hold switch to start and stop the counting function. It is not recommended to start from a dead stop at the starting flag and stop at the ending flag. 3. Place the Run/Hold switch in RUN when the marker on the vehicle passes the starting flag to activate the distance counting function. The console display numbers will increase, adding to the distance total as you drive. Drive the pre-measured course and place the Run/Hold switch in HOLD, when the marker on the vehicle passes the ending flag, to stop the distance counting function. The console display should display HOLD. Stop the vehicle in a level and safe area and continue with this procedure. 4. With the rotary dial still at DISTANCE ( ), press and hold the BLAST key for one second. Once the con sole is in, the speed calibration value will be displayed. Momentarily press BLAst and the word will begin to flash and the distance travelled will be displayed. See Illustration When the display shows distance ( is flashing), veri fy wheth er the number displayed is the ex act dis tance you drove (with in +/- 1-2 %). If not, press the + or - key to ad just the fig ure to match the dis tance you ac tual ly drove. If the display reads too high, use the - key to lower the dis played value. If the display reads too low, use the + key to raise the displayed value. 6. When the number shown on the display match es (as close ly as possible) the ac tu al dis tance driv en, you have ar rived at the cor rect cal i bra tion val ue. If you can not adjust the displayed distance to exactly match the actual dis tance driven, adjust the figure as close as possible to the actual distance. You may check the calibration number by momentarily pressing BLAST. The word will stop flashing and the number will appear. Exit by pressing BLAST for one second. The speed sen sor is now calibrated. To verify proper calibration, repeat the procedure a sec ond time. Write down the new speed calibration number and keep it in a safe place. If the cal i bra tion values are ever accidentally changed, you can simply re-en ter this num ber. MIN ADJUST TARGET VOLUME VOLUME / MINUTE TANK LEVEL AUTO MAN BLAST HOLD RESET AREA DISTANCE MODE (ALARM RESET) Illustration 15 WIDTH MODE SELECT TEST 36

37 Appendix D Fine Tuning Flowmeter Calibration Val ue This procedure is used to verify and fine-tune the flowmeter calibration. Every flowmeter is calibrated with water at the factory and stamped with a calibration val ue. Enter that value as a starting point and use this pro ce dure to fine-tune that value for your specific in stal la tion and spray ing application. This procedure should be re peat ed each time a new solution is being applied (differ ing so lu tions will have a different specif ic gravities and different flow char ac ter is tics) or when the flowmeter in stal la tion has been altered. Procedure 1. Put enough water in the sprayer tank to perform this test. (Preferably 100 gallons or more. The larg er the volume of water used, the more accurate will be the calibration.) 2. Start sprayer pump and turn on booms. Run enough water to purge all air from lines. Turn off booms but leave pump running. 3. Turn console rotary selector to the VOLUME po si tion. Select the counter (1-3) that you want to use. Press and hold the RESET button until the dis play reads CLEAr and then goes to 0.0 (about 2 seconds). 4. Turn on all booms, and run a known amount of water (preferably 100 gallons or more). * 5. Turn off all booms. Compare the console s VOLUME reading with the known amount of water run. If the two amounts are within one or two per cent, no fine tuning is required. If the two amounts are more than two or three percent dif fer ent, con tin ue with the next step. 6. With the console still in the VOLUME position, enter calibration (boom switches OFF, hold the BLAST button until red warning light comes on; about one second). The dis play will show the flowmeter calibration value and the icon. 7. Momentarily press the BLAST button. The icon will begin to flash and the total volume will be displayed. See Illustration When the TOTAL value is displayed, use the + or - button to adjust the value to match the amount of water run. 9. Momentarily press the BLAST button. The word will stop flashing and the flowmeter calibration number will be displayed. You will notice that the flowmeter calibration value has changed. Write down the new flowmeter calibration value. This is your fine tuned calibration value, keep it for future reference. 10. Exit calibration by holding the BLAST button until the red warning light goes out (about one second). * The most accurate method to measure the volume of water run is to place a container under EVERY nozzle and add together the amount from each nozzle. This assures that 100 percent of the water is collected and that all nozzles are spraying equally. It is important to perform this pro ce dure at a flow rate similar to that which will be used in the field. It is also possible to disconnect the main boom line and run it to a large measuring container but a valve must be installed and properly adjusted to simulate actual field conditions. MIN ADJUST TARGET VOLUME VOLUME / MINUTE TANK LEVEL AUTO MAN BLAST HOLD RESET Illustration 16 AREA DISTANCE MODE (ALARM RESET) WIDTH MODE SELECT TEST 37

38 Appendix E Flowmeter Assembly Important: Opening the flowmeter will void the Flowmeter Calibration value assigned to your unit. However, you may need to take the flowmeter apart for periodic cleaning or to remove an obstruction. If you can shake the flowmeter from end-to-end to produce a rattling sound (shaft-end play), or if you can blow into the meter from either end and cause the turbine to spin freely, your flowmeter does not need cleaning. If you cannot hear the rattling sound or get the turbine to spin freely, your flowmeter needs to be cleaned. See Illustrations below for reassembly instructions. Opening The flowmeter Cut the calibration tag retaining wire. Remove the screws and disassemble the flowmeter. Do not attempt to remove the sleeve bearings from the flowmeter housing. Use warm water and if necessary, a mild detergent and a soft bristle brush to clean all parts. Do not use solvents or diesel fuel to clean the flowmeter. A magnet works well for removing fine metallic particles from the turbine. Inspect all parts. Check for excessive bearing or shaft wear. The shaft will wear shorter until the turbine drags on the housing. When the shaft is worn to the point of drag, the turbine must be replaced. Complete assembly FM750 GFN Flowmeter Quad-ring P/N On a flat surface, place each housing half on end. Set and spin the turbine in each half. It should spin freely. If it does not spin freely, remove the turbine, wipe the shaft and try again. If is still does not spin freely, the shaft or bearings may have excessive wear. (Service may be necessary). assembling The flowmeter Stainless steel meters use a Teflon gasket. Sealants are normally not required. Plastic meters use an o-ring (Quadring). Apply a small amount of silicon grease for lubrication. Gaskets and o-rings may be reused several times but eventually may need replacement. Place the turbine in the non-sensor housing. Position gasket/o-ring; carefully place sensor housing over turbine. Drop all screws into holes. Hold nuts (and lock washers on stainless meters) in place and finger-tighten screws. Ensure proper placement of gasket/o-ring and evenly tighten all screws. Attach tag. After assembly, shaking flowmeter end-to-end should produce a rattling sound (shaft end play). Blowing into the meter from either end should cause the turbine to spin freely. If the turbine only spins from one direction, install the flowmeter so that the liquid flows in that direction (service may be required). For maximum accuracy the flowmeter should be mounted in a vertical position. Recalibration is required before field operation. Housing FM750 GFN Housing FM750 GFN (Non Sensor) Turbine P/N Complete assembly FM750 SS Flowmeter Gasket P/N Housing FM750 SS Turbine P/N Housing FM750 SS (Non Sensor) 38

39 Appendix F Radar Y Adapter Cables Ground Common B Ground 2. Signal Volts 4. N/C In-Cab John Deere Metri-Pack Connector 8000/9000 Series A Signal P/N P/N DICKEY-john Radar Amp Connector RADAR CONNECTOR SIGNAL PIN DICKEY-john Amp 2 DICKEY-john Cannon 3 DICKEY-john Deutsch 3 DICKEY-john Ford 2 DICKEY-john Packard B In-Cab JD (8000 & 9000 s Metri-Pack A Magnavox & Phillips Packard C Raven Conxall 3 Vansco Amp 2 In-Cab John Deere Y Connector 2 1 DICKEY-john Radar Cannon Connector 1 2 P/N Volts 2. Ground 3. Signal 4. Enable Volts Volts 3. Signal 4. Ground P/N DICKEY-john Radar Deutsch Connector P/N B C A. Ground B. Signal C. 12 Volts D. 12 Volts B DICKEY-john Radar Packard Connector A A D P/N Magnavox & Phillips Radar Packard Connector A A D B C B 1 2 DICKEY-john Radar Ford Connector 4 3 C A. 12 Volts B. 12 Volts C. Signal D. Ground D P/N D C Ground 2. Signal Volts 4. Enable P/N Raven Radar Conxall Connector 1 3 Vansco Radar Amp Connector P/N Ground Volts 3. Signal P/N

40 Appendix G Conversion Chart English to Metric When You Know Multiple By To Find LINEAR MEASUREMENT inches 25.4 millimeters feet meters yards meters miles 1.61 kilometers LAND MEASUREMENT square inches square millimeters square feet square meters square yards square meters acres.405 hectares square miles 2.59 square kilometers LIQUID MEASUREMENT fluid ounces milliliters pint liters quart liters gallons liters VOLUME cubic feet cubic meters cubic yards cubic meters DRY MEASUREMENT quart liters peck liters bushel liters FUEL CONSUMPTION 10 miles per gallon = 4.25 kilometers per liter Metric to English When You Know Multiple By To Find LINEAR MEASUREMENT millimeters.039 inches meters 3.28 feet meters 1.09 yards kilometers.62 miles LAND MEASUREMENT square millimeters square inches square meters square feet square meters square yards hectares 2.47 acres square kilometers square miles LIQUID MEASUREMENT milliliters fluid ounces liters pint liters quart liters 2.64 gallons VOLUME cubic meters cubic feet cubic meters cubic yards DRY MEASUREMENT liters quart liters peck liters bushels FUEL CONSUMPTION 10 kilometers per liter = 23.5 miles per gallon Conversion Abbreviations Symbols Symbols Symbols in. = inches pt. = pint km = kilometers ft. = feet qt. = quart mm2 = square millimeters yd. = yards gal. = gallon m2 = square meters ml. = miles ft3 = cubic feet ha = hectares in2 = square inches yd3 = cubic yards km2 square kilometers ft2 = square feet pk. = peck ml = milliliters yd2 = square yards bu. = bushel l = liters ml2 = square miles mm = milliliters dal = dekaliters (10 liters) fl oz. = fluid ounces m = meters m3 = cubic meters 40

41 Appendix H Data List for Data Logging On-The-Go Field No. No. Characters Parameter Value Description 0 1 Send Prefix D Current Target Rate 0 to (G/Lm, l/lkm, G/A, G/T, l/h) x 10, (G/Yd 2, l/m 2 ) x Actual Application Rate 0 to (G/Lm, l/lkm, G/A, G/T, l/h) x 10, (G/Yd 2, l/m 2 ) x Speed 0 to 999 (mph, km/h) x Pressure 0 Unused 5 1 Flow Rate 0 Unused Active Boom Width 0 to x 1 inch or x 1000 m 7 1 Boom Flags Bit 0 = Boom 1 0 = Switch Off, Boom Enable Off or Width =0 Bit 1 = Boom 2 1 = Switch On, Boom Enable On or Width > 0 Bit 2 = Boom 3 Bit 3 = Boom 4 Bit 4 = Boom Mode Flags Bit 0 = Console Hold 1 = Hold Bit 1 = Remote Hold 1 = Hold Bit 2 = PC Hold 1 = Hold Bit 3 = Auto 1 = Auto, 0 = Manual Bit 4 Unused Bit 5 = Blasting 1 = Using Blast Target, 0 = Normal 9 1 Status Flags Bit 0 = Rate Warning Application Error > 10% Bit 1 = Bad Cal EEPROM Checksum Failed Bit 2 = Tank Empty Alarm 41

42 Appendix I Totals Data List for Downloading Accumulated Data Field No. No. Characters Parameters Value Description 0 1 Send Prefix t (ASCII ) T request response Vehicle Number 0 to 255 Vehicle Identification Number 2 8 Date (of download) 01/01/06 to 12/31/99 Month/Date/Year 3 5 Time (of download) 00:00 to 23:59 Hour: Minute, 24 hour clock Area 1.0 to Lane Miles, Acres, Turfs, Lane km.00 to hectares 0 to Yd 2, m Volume 1.0 to Gallons or liters Distance 1.0 to Feet, Yards, Miles, meters or kilometers Average Speed on Area 1.0 to 99.9 mph or kph Highest Speed on Area 1.0 to 99.9 mph or kph 9 8 Date 1 Cleared 01/01/06 to 12/31/99 Month/Date/Year 10 5 Time 1 Cleared 00:00 to 23:59 Hour: Minute, 24 hour clock Area 2.0 to Lane Miles, Acres, Turfs, Lane km.00 to hectares 0 to Yd 2, m Volume 2.0 to Gallons or liters Distance 2.0 to Feet, Yards, Miles, meters or kilometers Average Speed on Area 2.0 to 99.9 mph or kph Highest Speed on Area 2.0 to 99.9 mph or kph 16 8 Date 2 Cleared 01/01/06 to 12/31/99 Month/Date/Year 17 5 Time 2 Cleared 00:00 to 23:59 Hour: Minute, 24 hour clock Area 3.0 to Lane Miles, Acres, Turfs, Lane km.00 to hectares 0 to Yd 2, m Volume 3.0 to Gallons or liters Distance 3.0 to Feet, Yards, Miles, meters or kilometers Average Speed on Area 3.0 to 99.9 mph or kph Highest Speed on Area 3.0 to 99.9 mph or kph 23 8 Date 3 Cleared 01/01/06 to 12/31/99 Month/Date/Year 24 5 Time 3 Cleared 00:00 to 23:59 Hour: Minute, 24 hour clock 25 1 Units E (45 16 ) or M (4D 16 ) E = English, M = metric 26 1 Mode L (4C 16 ), A (41 16 ) L = Lane, A = Agriculture T (54 16 ), D (44 16 ) T = Turf, D = Dust Where: T = Turf Ft2 L = Lane G/T = Gallons/Turf G/LM = Gallons/Lane Mile l/lkm = liters/lane kilometer G/A = Gallons/Acre l/h = Liters/Hectare G/Yd2 = Gallons/Sq yard l/m2 = Liters/Sq Meter 42

43 Appendix J Replacement Parts List RoadMaster System Components with Part Numbers The following replacement parts are available from: Micro-Trak Systems, Inc. 111 East LeRay Avenue P. O. Box 99 Eagle Lake, MN Toll-Free: Part Number Description Remote RUN/HOLD Sensor Kit 13181* RoadMaster Console Mount Kit Branch Cable Battery Cable RUN/HOLD Foot Switch Power Switch/Bracket Kit Run/Hold Switch/Bracket Kit RoadMaster Console, Standard Remote Hold/Blast Cable RoadMaster Reference Manual Optional Remote Blast/Run-Hold Switch Kit optional Tank Level Switch Ground Speed Sensors Part Number Description Astro II w/3-pin MT Base I & II M/P Astro 5 w/3-pin MT Base I & II M/P Vansco Radar Speed Sensor w/adapter Magnetic Wheel Speed Sensor Kit Magnetic Drive Shaft Speed Sensor Kit Flowmeters Part Number Description Optional 2-Pin and 3-Pin Weather-Pack Extension Cables Optional FM500 Flowmeter Kit Part No. W/P 2-Pin Part No. W/P 3-Pin Optional FM750GFN Flowmeter Kit Optional FM750SS Flowmeter Kit foot foot Optional FM 1000 Flowmeter Kit foot foot Optional FM 1500SS Flowmeter Kit foot foot Optional FM 750SS Flowmeter Kit w/ceramic Ball foot foot Optional FM 2000 P Flowmeter Kit Optional FM 3000 PSS Flowmeter Kit foot Optional FM 10/100 Flowmeter Kit Optional FM 270 Flowmeter Kit *The Console Mount Kit is available only as a kit, some parts are not available in individual components. Flow Control (servo) Valves Part Number Description Optional ¾ Micro-Trak Servo Valve Kit Optional 1 Flanged Servo Valve Kit (Butterfly) Optional 1½ Flanged Servo Valve Kit Optional 1 Servo Valve Hydraulic Flow Control (servo) Valves Part Number Description Optional 1 GPM HCV 1.0 Second Valve Optional 5 GPM HCV1.0 Second Valve Optional 5 GPM HCV 3.5 Second Valve Optional 10 GPM HCV 3.5 Second Valve Optional 15 GPM HCV 3.5 Second Valve Optional 20 GPM HCV 3.5 Second Valve Optional 35 GPM HCV 3.5 Second Valve Optional Bypass Dump Valve Optional Adjustable Pressure Relief Valve Optional 2-Pin, 3-Pin and 10-Pin Metri-Pack Extension Cables Part No. M/P 2-Pin Part No. M/P 3-Pin Part No. M/P 10-Pin foot foot foot foot foot foot foot foot foot foot foot foot foot foot foot Parts and design specifications subject to change without notice. 43

44 MANUFACTURED IN THE U.S.A BY: 111 E. LeRay Avenue P. O. Box 99 Eagle Lake, MN Toll-Free: Phone: Fax: P/N Rev. 3.0 Printed in the U.S. A.