micro-trak MT-400 LDI User manual

MT- 400
LDI
TM
LIQUID DE-ICER AND
ANTI-ICING AUTOMATIC
RATE CONTROLLER
REFERENCE
MANUAL
MANUFACTURED IN THE U.S.A BY:

2
MT- 400
LDI
TM
LIQUID DE-ICER AND ANTI-ICING AUTOMATIC RATE CONTROLLER
REFERENCE MANUAL
The MT- 400 LDI 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 MT-400LDI 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 MT- 400 LDI model MT 4-99 -LDI. 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 your dealer or distributor, or contact
Micro-Trak technical support for assistance.
Toll Free in U.S. or Canada: [phone] or [phone]
www.micro-trak.com •[email protected]
Manufactured in the U.S.A.
1305 Stadium Road
Mankato, MN 56001-5355
© Copyright 1998
Micro-Trak Systems, Inc.
Printed in the U.S.A.

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, shutoff 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.
Units under warranty should be sent prepaid, with dated proof-of-purchase, within thirty (30) days of discovering defect, to
the address below:
Mail and UPS:
Micro-Trak Systems, Inc.
ATTN: Service Department
1305 Stadium Road
Mankato, MN 56001-5355
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.
It is our goal to provide operators with a line of electronic equipment that will help build and maintain an efficient and
profitable operation.
We thank you for your purchase and hope that we can be of service to you in the future.
Micro-Trak Systems, Inc.
Extended Warranty Option
It’s simple! Just complete the registration for this product ONLINE at www.micro-trak.com
and we’ll extend your warranty for up to three years*, at no additional charge.
Registration information is for internal use only.
* Some limitations apply. See warranty statement for details.

4
Table of Contents
Warranty...................................................................................................................................................................................................... 3
Table of Contents ...................................................................................................................................................................................... 4
Component Parts and Assembly Hardware......................................................................................................................................... 5
Installation.............................................................................................................................................................................................6-11
Mounting the Display Console ...............................................................................................................................................................................6
Attaching the Power and Run/Hold Switch.......................................................................................................................................................6
Electrical Installation ..................................................................................................................................................................................................7
Connecting to Speed Sensor Cable.......................................................................................................................................................................8
MT-400 LDI Wiring Diagram.....................................................................................................................................................................................8
Mounting and Plumbing Flowmeter....................................................................................................................................................................9
Installing Flow Sensor Cable....................................................................................................................................................................................9
Manual Pressure Relief Valve, Range Adjust Valve, Servo, Throttling Valve ....................................................................................... 10
MT-400 LDI System Diagram ................................................................................................................................................................................ 11
Console Functions................................................................................................................................................................................... 12
Calibration .......................................................................................................................................................................................... 13-19
Entering Calibration Values.............................................................................................................................................................................13-14
Exiting Calibration .................................................................................................................................................................................................... 14
Drive Shaft Speed Sensor Calibration................................................................................................................................................................ 15
Entering Flowmeter Calibration Values............................................................................................................................................................ 16
Flow Cal Tag........................................................................................................................................................................................................ 16
Test Speed ................................................................................................................................................................................................................... 16
Fine-tuning Speed/Distance Calibration Value ............................................................................................................................................. 17
Fine-tuning Calibration........................................................................................................................................................................................... 18
Calibration Log Sheet.............................................................................................................................................................................................. 19
Pre-Application System Checkout ....................................................................................................................................................... 20
Operation............................................................................................................................................................................................ 21-23
Switches, Buttons and Display ............................................................................................................................................................................. 21
Rotary Switches.......................................................................................................................................................................................................... 22
Resetting System Counters ................................................................................................................................................................................... 23
Care and Maintenance ........................................................................................................................................................................... 23
Troubleshooting................................................................................................................................................................................ 24-28
General.......................................................................................................................................................................................................................... 24
Checking Individual Components ...................................................................................................................................................................... 25
Checking Console Inputs ....................................................................................................................................................................................... 26
Wiring Diagram.......................................................................................................................................................................................................... 27
Plumbing Troubleshooting Chart....................................................................................................................................................................... 28
Plumbing Guidelines .............................................................................................................................................................................. 29
Appendices......................................................................................................................................................................................... 30-33
Appendix A: Flowmeter Assembly .................................................................................................................................................................... 31
Appendix B: Conversion Chart............................................................................................................................................................................ 32
Appendix C: Replacement Parts List................................................................................................................................................................. 33
Notes ..................................................................................................................................................................................................... 34

5
Component Parts and Assembly Hardware
Before beginning installation, check the carton contents for the following items:
Owner’s Manual
P/N 14757
Console Mount Kit
P/N 13748
MT-400 Console
P/N 14756
14” Nylon cable ties (10)
P/N 12910
120” 10-pin extension cable
P/N 14316
72” Ignition Cable
P/N 14314
MT- 400
LDI
TM
LIQUID DE-ICER AND
ANTI-ICING AUTOMATIC
RATE CONTROLLER
REFERENCE
MANUAL
MANUFACTURED IN THE U.S.A BY:
Boom/ Servo/Flow Harness
P/N 14313
Power Cable
P/N 14315
Kit, Run/Hold Switch
P/N 14361
Kit, Power Switch
P/N 14360
Servo In-Line Adapter Cable
P/N 14463

6
Installation
Mounting the Display Console
Select a mounting location which seems most workable,
and that 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 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 1A.
Put rubber washers on carriage bolts and put the bolts
through the bracket holes from the inside out. Loosely attach
the mount knobs onto the bolts. Place console over carriage
bolt heads and tighten knobs to secure the console. See Illus-
tration 1B.
Illustration 1A
Illustration 1B
Drill ¼” (7mm)
holes for bolts,
or 3/16“ (5mm)
holes for self-
tapping screws.
Bolts
Lockwashers
and nuts
Rubber washer
Carriage bolts
Mount knob
CONSOLE END VIEW
Console easily adjusts for
side or dashboard mounting.
Mounting the Console Switch Brackets
Remove the mount knobs from sides of the console. Install
the 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.
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.
Attaching the Power and Run/Hold Control Switches
Red Wire
Black Wire
O
N
O
F
F
HOLD
RUN
Decal Hex Nut
Hex Nut
Washer w/Notch
Washer 1

7
Connecting to ignition to turn MT-400 system on/off.
Installation (cont)
Electrical Installation
The MT-400 must be connected to a 12-volt DC negative
ground electrical system.
POWER/BATTERY CONNECTION
Locate the power cable lead on the MT-400 harness and
route to the battery. In 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 2. Be sure there is a good
metal-to-metal contact. Connect the ORANGE wire to the
positive battery terminal.
Connect the power to the MT-400 console by plugging the
2-pin W/P tower on the power cable into the 2-pin W/P
shroud of the display console.
The MT-400 system harness includes a provision for either
using a switched (ignition) source or the optional power
switch to turn the system on.
If the switch is used, simply mount the switch bracket as
shown on Page 7, and plug the connector into the mating
cable from the console. If you want to use the ignition switch
to turn the system on and off, use your test light to locate a
terminal or wire connected to your ignition switch which is
“hot” when the ignition is turned on and “dead” when the
ignition is off. Using the 72” 2-wire extension cable, plug the
connector into the mating plug for the console and connect
the black wire to the switched power source (terminal or
wire). DO NOT connect the red wire.
Illustration 2
Illustration 3
Hot
(ORANGE)
10-Amp In-line
Fuse Required
Ground
(Blue)
+12 VDC
(RED)
Carefully route power
cable to a 12VDC source
Attach BLACK wire to
terminal or lead that is
“hot” with ignition on.
4-amp in-line fuse (Not Provided) required for unprotected circuits
Fuseholder
DO NOT connect
the red wire.
Tie back and tape o
Your MT-400 is equipped with an electronic memory which
does not require a constant supply of power to retain daily
totals or calibration values. This type of memory conserves
battery power and will not discharge the vehicle’s battery
when equipment is not in use.

8
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
MT-400 Wiring Diagram.
The speed sensor cable has a GREEN sensor body and mates
with the main harness cable having a YELLOW cable tie near
the 3-pin M/P connector. Make certain that you install the
correct sensor cable and connect it to the correct connector
on the main harness. The speed sensor and the flow sensor
are identical, but must be connected to the proper harness
connector. The speed sensor always connects to the main
harness lead with the YELLOW tie and flow sensor always
connects to the main harness lead with the GREEN tie. See
MT-400 Wiring Diagram. The optional Run/hold sensor,
also uses the same type of connector as the speed and flow
Installation (cont)
Connecting the Speed Sensor Cable
SENSOR IDENTIFICATION CHART
SENSOR SENSOR BODY COLOR MAIN HARNESS TIE COLOR
Speed Green Yellow
Flow Green Green
Run/Hold Black Gray
MT-400 LDI Wiring Diagram
MT-400 LDI CONSOLE
BOOM 1
BOOM 2
BOOM 3
SERVO +
SERVO -
FLOW SIGNAL
FLOE POWER
FLOW GRD
VES OUT
GND
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRY
WHT
BLK
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRY
WHT
BLK
+VES
SPEED POWER
SPEED SIGNAL
SPEED GND
R/H POWER
R/H SIGNAL
R/H GND
SWITCHED VES
+VES
GROUND
18”
18”
16 GA. BRN
16 GA. RED
16 GA. ORG
20 GA. YEL
20 GA. GRN
20 GA. BLU
20 GA. VIO
20 GA. GRY
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
A
B
C
D
E
F
G
H
J
K
A
B
C
D
E
F
G
H
J
K
10-PIN METRI-PACK SHROUD
10-PIN METRI-PACK TOWER
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
C
D
E
F
G
H
J
K
A
B
C
D
E
F
G
H
J
K
10-PIN METRI-PACK SHROUD
10-PIN METRI-PACK TOWER
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
10 FT. EXTENSION, PN 14316
BRANCH CABLE, PN 14313
.250 QD FEMALE (7)
BOOM 1
BOOM 2
BOOM 3
12V
GND
120”
GREEN TIE
FLOW
SERVO
A
B
C
A
B
C
3-PIN M/P
TOWER
3-PIN W/P
SHROUD
A
B
C
3-PIN M/P
150 SHROUD
3-PIN M/P
150 TOWER
72”
A
B
C
A
B
C
A
B
C
3-PIN M/P
150 TOWER
3-PIN M/P
150 SHROUD
A
B
2-PIN M/P
150 SHROUD
A
B
A
B
2-PIN M/P
150 SHROUD
2-PIN M/P
150 TOWER
YELLOW TIE
GRAY TIE
18 GA. RED
18 GA. BLK
18 GA. RED
18 GA. WHT
18 GA. BLK
18 GA. RED
18 GA. BLK
180”
P/N 13207
18 GA. RED
18 GA. BLK
A
B
C
3-PIN M/P
150 TOWER
SPEED
P/N 14314
YELLOW TIE
OPTIONAL POWER
SWITCH/BRACKET KIT
P/N 14360
RUN/HOLD
SWITCH/BRACKET KIT
P/N 14361
A
B
2-PIN W/P
SHROUD 2-PIN W/P
TOWER
A
B
16 GA. WHT
16 GA. BLK
14 GA. ORG
14 GA. BLU 180”
POWER CABLE, P/N 14315
FUSE HOLDER, 10A FUSE
5/16 IN RING CONN. (2X)
18 GA. RED +VES
18 GA. BLK IGNITION OR SWITCHED +VES
+VES
GND

9
The Flowmeter must be installed in the main boom line after
any strainers, return lines, or valves. Securely mount flowme-
ter (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 boom shut-off valves. The
flow meter 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 appropriate 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 to protect flowmeter during storage. (The flowmeter
may need periodic cleaning, so it should be easy to remove).
Installing Flow Sensor Cable
With the 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. Screw sensor all the way into hole
of flowmeter. Tighten 3/8” jam nut to lock sensor in place.
Uncoil flow sensor cable and carefully route it to meet 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 to
the right and the MT-400 Wiring Diagram.
NOTE: Sensors with GREEN bodies can be used for either
SPEED or FLOW but not for RUN/HOLD.
Connect flow sensor cable to green-tie console cable.
Illustration 4
Installation (cont)
Mounting and Plumbing Flowmeter
Illustration 5
Sprayer Line*
Locknut
Sensor
(green body)
Flowmeter
* NOT SUPPLIED
“L” Bracket*
Hose Clamps*
¾” NPT Male Fitting*
Hose Clamps*
Hose Clamps*
A B C
C B A
Flow Sensor
Cable Connector
Main Harness
Flow Connector
Green Tie

Tee “C”
Range
Adjust Valve
Tee “A”
Tee “C”
Tee “A”
Pressure
Relief Valve
10
If you have a positive displacement pump or a centrifugal
pump capable of generating excessive pressure, you must
install a pressure relief valve and adjust it to a safe maxi-
mum pressure. If a positive displacement pump is operated
without a pressure relief valve, damage may result to pump
or other plumbing component. See Illustration 6.
Range Adjust Valve
With oversized pumps, it may be necessary to install a range
adjust valve. The range adjust valve will reduce the pump’s
output to the rest of the system. Adjustment of this valve is
covered in the Pre-application System Checkout, page 20.
See Illustration 7.
Servo, Throttling Valves
The servo valve installs in an unrestricted return line to the
inlet of the pump or directly into the tank. DO NOT 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. DO NOT
install the servo valve in the agitation line. Slow response
time and marginal operation may result. The return line
should tee from the main line just after the throttling valve.
See Illustration 8. The throttling valve is used to limit the
output (set maximum output) of the pump to the flowmeter
and servo valve. The throttling valve is adjusted to put the
servo valve in its optimal operating range. Please refer to Pre-
application System Checkout for proper valve adjustment
procedure.
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. If using a Braglia
or other 12-volt control valve.
NOTE: The servo valve may be installed in the main spray
line. For in-line installations, you will need to cut the servo
cable and reverse the wires, or use optional adapter cable
P/N 14463 (See Illustration 9). Connect the WHITE wire to the
BLACK wire and vice versa. Failure to reverse the wires will
result in the servo valve operating backwards.
For positive
displacement pump
Installation (cont)
Manual Pressure Relief Valve
Illustration 9
Illustration 8
Illustration 7
Illustration 6
For oversized pumps
Return to pump
inlet or unrestricted
return to tank
Servo Valve Cable
From Pump Throttling Valve
To Flowmeter
Servo Valve
Servo
Flowmeter
From Pump