CS102M1A Manual
CS102 Spreader Control Manual
CS102M1A
General Description
The CS102 implements a digital rate control for granular and liquid systems typically used to regulate
snow and ice highway spreading equipment. The CS102 is a full featured granular control for the
spreader systems using conventional conveyor & spinner. The CS102 will also operate an auxiliary liquid
pump for pre-wet applications. The CS102 can alternately be configured to operate a de-icing system by
connecting the conveyor valve drive to a large volume liquid pump. The CS102 uses advanced digital
techniques to regulate the shaft speed of the conveyor in direct response to vehicle speed. The granular
spread rate is calibrated and regulated in true units of "pounds per mile". The pre-wet control is
calibrated for "gallons per ton" and the De-ice control is calibrated for "gallons per mile". The CS102
accommodates both closed loop and open loop control with calibrations for ground speed input and shaft
driven pulse sensor feedback.
Features:
> Automatic ground speed and manual modes for rate control
> Blast and Pass (remote switch spot mode)
> Controls both drag chain conveyor or auger (screw) type spreaders
> Four pre-set spinner output settings, detent switch
> Eight different granular materials, with individual data logging
> Granular control, 20 to 3000 pounds/mile, open loop or closed loop shaft control
> Liquid pre-wet control, 0.5 gal/ton to 12 gal/ton, open or closed loop shaft control
> De-ice control, 250 gal/mile, open or closed loop rate control
> Electronic or mechanical transmission sensor interface (mph)
> PWM closed loop current control or open loop voltage control
> Digital switch input for gearbox or spot spreading options
> Dual time based data logging; spreader miles, total material output (pounds) per product
> Supports field printing and PC interface, RS232 interface
> Supervisory: spread rate limits, manual lockout, spot/pass, Blast, material types
> Software upgrade via field lap top
> English or metric operation
> 10 year real time clock
The CS102 employs a PWM current control for precise open loop shaft control. The CS102 calculates
and displays the spread rate and accumulated pounds delivered. The spinner and conveyor automatically
start and stop with the vehicle. The digital controller has complete system surveillance with alarm
indication for conveyor overrun, failed valve coils, cables and sensor functionality. This compact design
is easily adapted to most console/cab layouts. The operator benefits from the large format numeric
display with easy to use feed rate and lane width controls.
Field Printer (option)
The CS102 incorporates a standard RS232 communications port for use with remote communications
devices. Using the optional field printer p/n FP100 allows you to extract the internal. The print-out
includes accumulated totals for both recent and annual usage's, total pounds of material for all eight
granular product types, total gallons of liquid, total miles in auto and manual, calibrations, dates and
times. Simply connect the printer to the comm. port, turn power ON to the CS102 to print a short menu.
Use the Rate knob to select the menu item number. Press Blast to print. When the printing is completed
turn the power switch OFF and remove the printer connection.
Operational features
The CS102 has a manual mode that gives the operator direct electro-hydraulic control over the conveyor
and spinner valves. Manual mode is useful for testing the basic hydraulic system and as backup
operation should a sensor fail. Manual mode does not conserve spreading material and does not
automatically shut off the feed rate when the vehicle comes to a stop. In manual the display still shows
lbs./mile but as the vehicle moves, this number will move up and down since there is no ground speed
regulation.
Blast will instantly output 100% and normally is used to lay down a thick coverage of material.
Alternately, Pass instantly turns the conveyor off to allow the spreader vehicle to pass or be passed. Both
of these features will operate any time the respective switch is pressed, regardless of man/auto mode or
vehicle speed. The Blast has an optional off-delay timer that holds the Blast output on for up to 30
seconds. If the operator needs to stop the timer, press the Blast switch momentarily and the Blast timer
will instantly end.
To unload the spreader select manual mode and turn the Rate knob up (full CW). This will unload
conveyor and not add to the data logging, but only while the vehicle is stopped.
Pass works as a push on / push off function. The first push will activate the Pass feature (conveyor off)
and the second push will de-activate the Pass feature (conveyor off). There is a option for remote Pass,
see the calibration procedure.
The automatic Rate control is a hands free operation that maintains a constant feed rate. The operator
adjusts the granular rate using the display. The granular rate ranges from 20 lbs/mile on the lowest
setting up to 3000 lbs/mile at the maximum setting. There is a spread rate limit that's adjustable from 100
to 3000 lbs/mile
Pulses from the transmission sensor create the ground speed signal. When the vehicle is stopped
(zero MPH) the display will flash (dimming) the desired spread rate to indicate no ground speed pulses
are being received. Once the vehicle begins moving and the pulses are present, the display stops
flashing, the feed rate is displayed steady (non-flashing). As the vehicle begins moving the conveyor
shaft rpm will automatically increase in direct relation to the vehicle speed, keeping the spread rate
constant. At 1/2 mph the spinner automatically drives to a preset level.
The CS102 calculates the accumulated pounds of the delivered material. The total weight is always
being recorded whether in Manual, Auto or Blast mode. There are eight internal accumulators, one for
each product. The display shows this value in 10's of lbs. So that a reading of 1200 will be a weight of
12,000 lbs. All eight product totals are retained and are always available for printing.
The operator can quickly view and/or clear the accumulated pounds of the selected product with the
Lane switch set to Accum. (prod). To clear hold down the Blast switch. The display will show “AC 30”
The 30 will decrement to 0 (approx 3 seconds) and then clear the accumulator.
To change the selected product. First, set the Lane switch to the Accum. (Prod) position and press the
Pass switch up (select). The current product number will show. Next, continue to hold the Pass switch up
and turn the Rate knob to select a different product. Release the Pass switch and the new product is
locked into memory.
Front Panel Controls
The mode switch is located in the upper left corner and is used to select three operational modes.
Off……………. When the mode switch is Off all power is removed from the valve drivers, sensors and
comm. port. Do not use the mode switch to stop and start the valve drive in order to
implement spot spreading. Use instead, the Pass switch for spot spreading.
Granular……... The granular position allows the operator to use the feed Rate knob to directly adjust the
granular output, while viewing the feed rate in lbs./mile on the display.
Run Pre-wet… The pre-wet mode operates both the granular spreader and a small liquid pump. The
ratio of liquid to granular material is gallons per ton.
Set Pre-wet….. The operator uses this selection to view and/or re-adjust the liquid -granular ratio using
the feed Rate knob.
De-icing……… The De-ice mode controls a large liquid pump to deliver liquid at a fixed rate, gallons per
mile. There is no spinner output in this mode. Granular spreading equipment and the
large liquid tank required for De-icing cannot both fit onto the same truck. The CS102
uses the same output to run either the granular control valve or the De-ice control valve,
but not both simultaneously. The vehicle wiring and hydraulic system are changed when
switching between the granular and De-ice modes.
The lane switch is used to adjust the spinner output and to operate some special features. It’s located in
the lower left corner of the panel.
Off ……………. Turns the spinner output off. The display denotes this mode with a small upper case 0 in
the left most digit.
1, 2, 3, 4………. Spinner output is active. The spinner speed has four preset levels established in the
calibration procedure. The spinner speed is typically set using actual granular material
since the material weight will tend to alter the spinner speed. The spinner drive can be
programmed to shut off at zero mph or remain on at zero mph. In manual mode the
spinner always remains on at zero mph, requiring the operator to manually set the
spinner OFF.
Accum (Prod). View the accumulated pounds dispensed. Similar to a trip odometer this accumulator
can be reset to zero. The alternate use for this position is to change the product. Hold the
blast switch and use the feed Rate knob to select the product number
Cal ……………. This position is used to place the CS102 into the calibration mode. To change
calibration settings requires a pass code.
Man ………….. This position sets the CS102 into a manual mode. Use the Pass/Blast switch to set the
manual mode on or off. The power up default is auto mode. The calibration procedure
allows the installer to disallow manual mode by the operator.
The Rate knob is located in the lower right In Automatic mode the Rate knob adjusts the desired
application spread rate. The full CCW position of the Rate knob always turn the conveyor OFF,
regardless of the vehicle speed or selected mode. In Manual mode the Rate knob directly sets the
electro-hydraulic output for the conveyor valve.
The display shows numeric values between 0 to 99999. For automatic and manual mode the display
shows the spread rate in lbs./mile. When the power switch is in the Total position the display shows
pounds/10.
Display
Explanation
o
Rate knob full CCW (conveyor off), spinner off
Minimum feed rate, spinner on
Manual mode, conveyor = 0% output
Blast is active, timer on. yy is timer (seconds)
Show the selected product number, (# = 1 thru 8)
Clearing the product totals, xx = 3 sec. timer
Programming menus, zz = menu number 1-56
Error codes, zz = error number 01 thru 12
0
20
-00bL yy
Prod#
AC xx
P zz
E zz
Error codes
The CS102 can detect several system failures. Each of these is presented to the operator through a set
of error codes. If during operation an error should occur the operator should make note of the code (E01,
02, etc.) and then press the Blast switch to clear the error. If the error does not clear then system will
require immediate attention by a qualified technician. Error codes may be reset by pressing Blast.
Er 01
Er 02
Er 03
Er 04
Er 05
Er 06
Er 07
Er 08
Er 09
Er 10
Er 11
Er 12
no conv Fb pulses / automatically cross calibrates to open loop calib
no conv Fb pulses / cross calib not available
conveyor (De-ice) valve, over current
conveyor (De-ice) valve, open circuit
spinner valve, over current
spinner valve, open circuit
cpu watchdog, cycle power to reset
failed fuse, replace with 5x20mm 5 amp
Pre-wet coil, over current
Pre-wet coil, open circuit
Pre-wet feedback fail
De-ice feedback fail
PROGRAMMING
Introduction
The CS102 uses the front panel to view and modify all settings within the computer's memory. There are
no special tools required. The front panel knobs and switches let you view each setting. To make
changes to the programmed values requires you first enter a password. Without a password you can view
any of the internal memory settings. Each program variable is selected by scrolling through a list of
menus. Each menu is numbered, P01 thru P56.
Before you start --- think safety
When making program modifications the CS102 will automatically activate the hydraulic functions. Prior
to programming ensure the vehicle is safe and all personnel in the area are notified.
How to access and edit the calibration data ( GoTo and Enter commands)
2.
3.
Select program mode P01
Power switch = On (any mode) + Lane switch = Cal. Display shows [=====] five double-dashes
Press and hold Pass switch and adj. Rate knob = P01. [P01 is the password menu]
Hold the Blast switch, adjust Rate knob until display = password (4836)
Release Blast switch, You are now ready to GoTo any program menu Pxx and make changes.
4.
5.
GoTo Pxx Select the desired menu number to edit (or view)
Hold Pass sw. and adj. Rate knob until the display = Pxx ( xx = menu number)
Release the Pass sw., display = current stored value
6.
7.
Edit (or view) existing value
Hold Blast and adj. Rate knob until the display = [new value]
Release the Blast sw to save the value into memory.
1.
Programming tips
While in the Calibration mode and you wish to know the menu number you’re presently viewing, simply
press the Pass switch but do not move the Rate knob.
When you press and hold the Blast switch while turning the Rate knob, the display will scroll through the
full range of data values for that menu. When the menu requires a choice between features instead of
numeric data the display will show alpha symbols, such as [rP] which stands for remote pass mode.
When you release the Blast switch you will notice a brief dimming of the display. This indicates a save to
memory has been made.
The calibration mode has some special features designed to assist the installer. Some of the menus allow
the conveyor or spinner to operate while you're in program mode or read the sensors output pulses or
report valve drive in milliamps, etc. example: P20 is where you set the mph calibration (cts/mile) but
P20 + Prod lets you view actual mph [P20 + Prod means at menu P20 rotate the Lane switch CW one
position to the Prod position to view the actual mph]. The + Prod option is available on several menus.
The task of programming uses the above procedure, notably steps 4 thru 7 which are repeated for each
program setting you wish to edit. When you have completed editing the CS102's settings you can return
to the run mode by moving the Lane switch to the Off position. As long as the unit is powered up the
password is retained. This allows you to move between calibration mode and a run mode without reentering the password each time.
Programming menus
Menu #
Variable name
Range or Selection
Information settings
P01
Password
[4836]
P02
Truck number
[0 - 250]
P03
Serial number
[ set by factory ]
P04
Checksum
[ xxxx ] used program verification
P05
Firmware version
[ yyyy ] used for program upgrades
Valve settings for granular mode
P10
PWM frequency
[30-250 hertz]
P11
Conveyor min speed
[2-100%] or [50-2500ma]
P11 + Prod
Conveyor min speed
[view feedback hertz if conveyor if set to closed loop]
P12
Conveyor max speed
[2-100%] or [50-2500ma]
P12 + Prod
Conveyor max speed
[view feedback hertz if conveyor if set to closed loop]
P13
Conveyor cross calib.
[10-999 max hertz] or [nA = no cross calib]
P14
Conveyor test mode
[view conv. valve ma] Rate knob sets conv. output
P14 + Prod
Conveyor test mode
[view conv. feedback hertz] Rate knob sets conv. output
P15
Lane 1 spinner speed
[0-100%] or [10-2500ma]
P15 + Prod
Lane 1 spinner current
SC = actual spinner current
P16
Lane 2 spinner speed
[0-100%] or [10-2500ma]
P16 + Prod
Lane 2 spinner current
SC = actual spinner current
P17
Lane 3 spinner speed
[0-100%] or [10-2500ma]
P17 + Prod
Lane 3 spinner current
SC = actual spinner current
P18
Lane 4 spinner speed
[0-100%] or [10-2500ma]
P18 + Prod
Lane 4 spinner current
SC = actual spinner current
Calibration settings for pulse sensor inputs
P20
MPH calib, counts / mileDisplay [250 - 15280] X10 actual [2500 - 152800]
P20 +Prod
View actual mph
Press Blast use Rate knob, display = speedometer
P21
mph sensor type
[dc - AC] dc = hall effect and World, AC = VRM
P22
20 mph simulated
[S-OFF / S-on] simulates a 20 mph signal input
P30
Conveyor calib
[50 - 1499 lbs / minute open loop mode]
[0.020 - 1.499 lb/pul closed loop mode]
P31
Conveyor pulse dump
[cd 10] hold Blast, display counts down 10,9,8…2,1,0
release Blast to view the accumulated pulses received
from the conveyor sensor. Use the Rate knob to adjust
the conveyor speed. Rate knob = CCW stops the
conveyor. Blast resets the accumulated pulses.
Granular Product settings
Note, Product 1 is always the product used to calibrate the conveyor
P32
Prod 2
[ratio] = weight prod 2 / weight prod 1
P33
Prod 3
[ratio] = weight prod 2 / weight prod 1
P34
Prod 4
[ratio] = weight prod 2 / weight prod 1
P35
Prod 5
[ratio] = weight prod 2 / weight prod 1
P36
Prod 6
[ratio] = weight prod 2 / weight prod 1
P37
Prod 7
[ratio] = weight prod 2 / weight prod 1
P38
Prod 8
[ratio] = weight prod 2 / weight prod 1
Granular System settings
P40
Conveyor servo mode
[OP = open loop] [CL = closed loop]
P41
CS102 Run mode
[An] = (both auto and manual modes enabled)
[AO] = (auto mode only)
P42
Maximum feed rate
[100-3000] lbs/mile. Limits operator's upper setting
P43
Blast off delay timer
[1-10 seconds] [b-OFF timer off, Rate knob = CCW]
P44
Blast rate
[rl] Blast = maximum valve [rA] Blast = maximum rate
P45
Option input
PAS = remote pass input
gEAr = gearbox input
BLA = Blast,
PSI = pressure sw input
P46
`
Gearbox ratio
[nA = not available] [.20 - 5.0] = gearbox ratio
P47
Spinner mode
[A OFF] = (spinner will turn on/off with mph)
[n OFF] = (spinner will NOT turn on/off with mph)
P48
Conveyor drive
[C-PEr] calibrations in percent mode, %
[C-cur] calibrations in current mode, ma
P49
Spinner drive
[S-PEr] calibrations in percent mode, %
[S-cur] calibrations in current mode, ma
Real time clock settings
P50
Minutes
0-59
P51
Hours
0-23
(24 hour mode)
P52
Day of week
1-7
(Sun - Sat)
P53
Day of month
1-31
P54
Month
1 - 12
P55
Year
1997 - 2096
P56
metric/English
[rc = metric] [EH = English]
(Jan - Dec)
(Y2K compliant)
Pre-wet settings
P60
Maximum pre-wet rate
[2.0 - 16.0 gal/ton] set operators upper limit
P61
Max pre-wet output
[2.00 - 23.99 gal/min] open loop measure at valve max
[200 - 2399 pul/gal] closed loop use sensor manf rating
P62
Min pre-wet output
[0.1 - 2.0 gal/min] open loop measure at valve min
for closed loop operation this variable is not used
P63
Pre-wet valve min
[1-97%] set for minimum acceptable spray pattern
P64
Pre-wet valve max
[1-97%] set for maximum liquid pump output
P65
Pre-wet servo mode
[P OPn = open loop] [P CLO = closed loop]
P66
Pre-wet drive
[P PCn = percent mode] [P CUr = current mode]
P70
Maximum De-ice rate
[10 - 500 gal/mile] set operators upper limit
P71
Max De-ice output
[2.0 - 149.9 gal/min] open loop measure at valve max
[2.0 - 149.9 pul/gal] closed loop use sensor manf rating
P72
Min De-ice output
[0.5 - 20.0 gal/min] open loop measure at valve min
for closed loop operation this variable is not used
P73
De-ice valve min
[2-100%] set for minimum acceptable spray pattern
P74
De-ice valve max
[2-100%] set for maximum liquid pump output
P75
De-ice servo mode
[d OPn = open loop] [d CLO = closed loop]
P76
De-ice drive
[d PCn = percent mode] [d CUr = current mode]
De-ice settings
Comm Port
The CS1 is equipped with a communications port on the front panel. The purpose of this comm. port is to
provide the user with a convenient method for transferring data to and from the controller using a
standard laptop computer. There are two terms used to define data transfers. Upload defines the action
of sending data from the laptop to the controller and download is the act of transferring data from the
controller to the laptop.
The controller contains an application program within its internal memory that completely defines how the
unit will function as a spreader control. From time to time the factory may create a new version of the
application program. Typically this is done to fix a bug, improve or add a new feature. The user can
upload a new application program (upgrade) through the comm. port using a laptop computer.
To perform an upload procedure the user needs the following;
1) a comm. port cable ref. p/n CS100C1A
2) a laptop computer running Windows™ with a resident terminal emulator program
3) the new (upgraded) application program, this may be contained a disk or received by e-mail
The file naming convention used for application program upgrade is as follows
general form: CS102Fyy.s19
xx = the family name
yy is the version
example:
CS102F1A
01 family, version 1A
Note, all application programs for the CS1 controller are under copyright protection. All rights are
reserved by Ditco Inc. You are NOT authorized to copy or use this program for any reason other
than to upgrade an existing version within a CS1 controller
As additional security the integrity and identification of the application program can be confirmed by the
checksum. The program version checksum can be determined using the standard program mode for the
CS1 using the front panel controls, see section PO4 cs and PO5 f/w version
The following procedure is for a laptop connection to the front panel comm. port. The connector is a 4 pin
Conxall. The proto call is as follows:
Baud rate
Data bits
Parity
Stop Bits
Flow control
Transmit buffer
ASCII setup
9600
8
None
1
Xon / Xoff
set as low a speed as possible (1)
character delay 1ms
With your terminal emulator setup and the cable installed, Power up the CS1
“ “ indicate the characters to be typed, use enter key to send
Type “xy” this will return with a menu (this command must be lowercase)
Type “p” this will set the CS1 up for program mode (the CS1 will respond with Ready)
From your terminal emulator Transfer / send text file (send CS102F2Y.S19)
Type “v” this will verify the checksum within the CS1
VERY IMPORTANT If the process of re-programming the CS1 fails, either due to incorrect terminal
settings or power interruption or other causes, the CS1 may not be able to try again. If this happens you
will have to send the unit back to the factory for re-programming.
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