Flex4 Pro Operators Manual
®
SINCE 1966
FLEX4 PRO
™
PUBLIC WORKS CONTROL SYSTEM
Operator’s Manual
FLEX
PRO
OPERATOR’S MANUAL
Safety Notices ........................................................................................................1
Disclaimer ............................................................................................................................ 1
Introduction ........................................................................................................... 3
Features .............................................................................................................................. 3
Component Overview ........................................................................................... 5
Flex4 Pro tablet .................................................................................................................. 5
Switch module functions...................................................................................................... 8
Rate control module ............................................................................................................ 9
Output module ................................................................................................................... 11
Miscellaneous components ............................................................................................... 15
Installation ............................................................................................................17
Operator switch module mounting bracket........................................................................ 17
Ram mount bracket installation ......................................................................................... 18
Operate screen overview ....................................................................................27
Display settings (Camera/Display/Alarms) ........................................................................ 29
Operation ..............................................................................................................31
Pre-operating checklist ...................................................................................................... 32
Spreading material ............................................................................................................ 32
Blast................................................................................................................................... 33
Pause ................................................................................................................................ 34
Material selection .............................................................................................................. 35
Unload material ................................................................................................................. 36
Manual ground speed override.......................................................................................... 38
Automatic manual control channel override ...................................................................... 39
Driver login ........................................................................................................................ 40
Route selection .................................................................................................................. 40
Boom section control ......................................................................................................... 41
Anti-ice feature .................................................................................................................. 42
Accessory sensors ............................................................................................................ 42
Hydraulic accessory tool operation ................................................................................... 44
Current and season run totals ........................................................................................... 44
Flex4 Pro programming ......................................................................................47
Passcode restrictions ........................................................................................................ 47
Keyboard functions............................................................................................................ 48
Flex4 ProTM Control System
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/1
OPERATOR’S MANUAL
System programming ......................................................................................... 53
Operate mode (F1) ............................................................................................................ 53
Anti-ice button mode feature ............................................................................................. 53
Granular Channel Setup (F2) ............................................................................................ 55
Granular rate setup ........................................................................................................... 56
Granular configuration (f2) ................................................................................................ 59
Liquid channel setup (f3) ................................................................................................... 62
Liquid rate setup ................................................................................................................ 63
Boom configuration (liquid/Anti-Ice) .................................................................................. 66
Auxiliary control channel configuration (f5) ....................................................................... 71
Accessory sensors (F9) .................................................................................................... 72
System setup (F10) ........................................................................................................... 84
Blast setup ........................................................................................................................ 84
Date and time .................................................................................................................... 85
Units and language ........................................................................................................... 86
Service .............................................................................................................................. 87
Troubleshooting ................................................................................................................ 89
Output module setup (f11) ................................................................................................ 91
Data logging (F12) ............................................................................................................ 93
Driver setup ....................................................................................................................... 95
Calibrations ....................................................................................................... 103
Material and spinner system response calibrations (f6) ................................................. 103
Recording calibration data .............................................................................................. 104
Maintaining calibration accuracy ..................................................................................... 105
Granular drop test calibration .......................................................................................... 106
Liquid drop test calibration (F6) ...................................................................................... 109
Auxiliary system response and drop test ........................................................................ 112
Spinner system response calibration .............................................................................. 112
Import/export data files .................................................................................... 121
Passcode enabled........................................................................................................... 121
Export configuration files ................................................................................................. 121
Export log data files ......................................................................................................... 122
Import configuration files ................................................................................................. 125
Capture screen shot ......................................................................................... 127
Diagnostics ........................................................................................................ 129
Perform a Diagnostics check (f7) .................................................................................... 129
Display PCECU ............................................................................................................... 131
Control module ................................................................................................................ 131
Output module ................................................................................................................. 135
Troubleshooting ................................................................................................ 137
Appendix A ........................................................................................................ 143
Appendix B Converting Constants.................................................................. 145
Fine Tuning Application................................................................................................... 145
Calculating Spreader Constants ..................................................................................... 146
Appendix C ......................................................................................................... 147
2/
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
SAFETY NOTICES
Safety notices are one of the primary ways to call attention to potential
hazards. An absence of specific alerts does not mean that there are no
safety risks involved.
This Safety Alert Symbol identifies important safety
messages in this manual. When you see this symbol,
carefully read the message that follows. Be alert to
the possibility of personal injury or death.
Use of the word WARNING indicates a potentially hazardous
situation which, if not avoided, could result in death or serious
injury.
Use of the word CAUTION with the Safety Alert Symbol indicates a
potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
Use of the word CAUTION without the safety alert symbol
indicates a potentially hazardous situation which, if not avoided,
may result in equipment damage.
DISCLAIMER
DICKEY-john reserves the right to make engineering refinements or
procedural changes that may not be reflected in this manual. Material
included in this manual is for informational purposes and is subject to
change without notice.
Flex4 ProTM Control System
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SAFETY NOTICES / 1
OPERATOR’S MANUAL
Flex4 ProTM Control System
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SAFETY NOTICES / 2
OPERATOR’S MANUAL
INTRODUCTION
The DICKEY-john Flex4 ProTM Control System can simultaneously control
both granular and liquid snow and ice removal materials. Separate
channels for granular and liquid precisely controls and maintains the
desired applications.
The flow of material varies automatically in proportion to the changes in
ground speed so the application rate remains uniform. When Automatic
mode is enabled, spreading automatically starts when the truck begins to
move and automatically stops when the truck stops.
The operator interface consists of a:
•
•
Flex4 ProTM Tablet
Operator Switch Module
Desired material application rates are entered on the Setup screens by
attaching a keyboard.
Figure 1e
Flex4 ProTM Tablet and Remote Operator Switch Module
FEATURES
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•
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•
•
•
Flex4 ProTM Control System
6010541 Rev A
Color touch screen display with stylus
4 channel closed-loop control of granular, liquid, auxiliary (liquid or
granular), and spinner functions
Year-round application for roadside spraying, berming, and operation
of hydraulic tools
Day/night mode
Optional camera to view rear of truck to monitor material dispensing
and to avoid potential accidents
Compatible with vehicle and fleet data management systems
INTRODUCTION / 3
OPERATOR’S MANUAL
4 / INTRODUCTION
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
COMPONENT OVERVIEW
Components included with the Flex4 ProTM Control System:
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•
•
•
•
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Flex4 ProTM tablet
Flex4 ProTM tablet mounting plate, bracket, and hardware
Rate control module
Operator Switch Module
Operator Switch Module mounting bracket and hardware
Cab power harness
Rate control module harness
PCECU (power controller ECU)
USB port hub
USB-CAN adapter
DC-DC converter
Optional components:
•
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•
•
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•
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•
NOTE: Contact DICKEY-john Technical
Support to order optional
components at
1-800-637-3302.
FLEX4 PROTM TABLET
The Flex4 ProTM tablet is a color touch screen display providing
simultaneous viewing of:
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•
•
•
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•
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•
Flex4 ProTM Control System
6010541 Rev A
10’ CAN extension harness
Output module and harness
Solenoid driver
Electric motor/pump driver
Camera 4.3mm lens
Camera to USB adapter cable
12V power adapter camera cable
20’ camera extension
Feedback sensors
Rates
Spread width
Vehicle speed
Spread direction
Road temperature
Joystick selection
Accessory input monitoring
Multiple vehicle cameras
COMPONENT OVERVIEW / 5
OPERATOR’S MANUAL
Figure 2
Flex4 ProTM Tablet
TABLET SPECIFICATIONS
Physical and Environmental Characteristics:
Dimensions with case:
10.43”W x 7.07”H x 0.70”D
(265 mm W x 179.6 mm H x 17.9 mm D)
Operating Temperature: 32 degrees F to +120 degrees F
(0 degrees C to +49 degrees C)
Storage Temperature:
-22 degrees F to +160 degrees F
(-30 degrees C to +71 degrees C)
Humidity:
5% - 95% non-condensing
The Flex4 ProTM tablet should not be turned on until product
temperature stabilization occurs when exposed to different
temperature extremes.
Cab temperatures should be above 32 degrees for proper
operation.
Humidity levels should be below 95% before powering on device.
6 / COMPONENT OVERVIEW
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
TABLET CONNECTIONS
Two tablet connections on the Flex4 ProTM tablet are used.
1. Tablet power cable
2. USB port (connects to Tough Hub)
Figure 3
Flex4 ProTM Tablet Connections
volume power adjustment button USB port Power cable Stylus Flex4 ProTM Control System
6010541 Rev A
COMPONENT OVERVIEW / 7
OPERATOR’S MANUAL
OPERATOR SWITCH MODULE
The Operator Switch Module consists of buttons that control material
application rate and spread width knob to adjust spinner speed and regulate
spreading of material. The module is backlit for visibility during night
operation and is mounted next to the display, driver seat arm rest, or on side
of the electronic joystick hydraulic controller.
Figure 4
Operator Switch Module
Spread Width Knob SWITCH MODULE FUNCTIONS
AUTO ON/OFF
The Auto On/Off button regulates the amount of material applied in relation
to the ground speed and turns the application of product on or off.
PAUSE
Pause button stops applying material but continues to calculate the total
miles driven. Auto mode must be active for the Pause feature to operate.
BLAST
The Blast button applies material at a pre-programmed dispersal rate in
Auto mode and manual override with Auto Switch in ON or OFF position.
RATE (-)
The Rate (-) button decreases the amount of pre-programmed material with
each button press in Auto mode and manual override.
RATE (+)
The Rate (+) button increases the amount of pre-programmed material with
each button press in Auto mode and manual override.
SPREAD WIDTH KNOB
Spread Width Knob adjusts the spinner speed to regulate material spread
width. The spread width percentage displays on the console. Pressing the
spread width knob also selects a channel to adjust.
8 / COMPONENT OVERVIEW
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
USB DATA PORT CONNECTION
USB data port for data download and keyboard connection is located below
the switch module. The USB port can be used for the following purposes:
– Transmission of current operation information and logged data for
export to external hardware.
– Accepts a USB memory device for exporting logged spread data for
transfer to a laptop computer.
– Import of system firmware updates to tablet and master control
module from USB memory device.
– Imports system configuration files to program each tablet and
master control module with system calibration values.
Figure 5
USB Data Port Connection
Spread Width Knob USB Port RATE CONTROL MODULE
The Rate Control Module houses the system’s primary interface device. All
system parameters, constants, and memory are stored in the module and
controls material application by interfacing with valves and feedback
sensors.
1. Select an area on the vehicle chassis to mount the Rate Control
Module that allows for easy hookup and access.
2. Use the enclosure as a template to mark the location of the mounting
holes.
3. Drill four 9/32 inch diameter holes where marked.
Flex4 ProTM Control System
6010541 Rev A
COMPONENT OVERVIEW / 9
OPERATOR’S MANUAL
Figure 6
Rate Control Module
7.45” 7.0” 3.93” 6.80” IMPORTANT: Do not use the enclosure as a guide when drilling. Do
not overtighten nuts as this may damage the mounting
tabs of the enclosure.
The module can be mounted in any of the following orientations:
Figure 7
Acceptable Orientation
PREFERRED ACCEPTABLE ACCEPTABLE Do not install the module in any orientation other than shown in
(Figure 7). The connection wires must not be mounted upward as
moisture can collect inside the unit and damage the circuits.
4. Mount with the label side of module facing out. Do not mount with the
connector facing up (see Caution).
Connect any additional adapter harnesses to the module harness.
The Rate Control Module harness can accept an extension harnesses or
the output harness.
10 / COMPONENT OVERVIEW
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
The Rate Control Harness provides a connection to the following inputs:
– 1 granular control channel
– 1 liquid control channel (prewet or anti-ice)
– 1 auxiliary/spinner control channel (liquid or granular)
– 1 auxiliary channel (liquid or granular channel)
– 2 application rate sensors
– 4 hydraulic valves (PWM)
– 1 down pressure sensor
– 1 control valve (Servo)
– 2 flow meters
– 1 gate height sensor
– 1 ground speed sensor
– 1 remote on/off
– 2 digital sensors
– 1 hopper level sensor
– 1 tank level sensor
– 2 6-pin Servo connectors
– 1 road/air temperature sensor adapter (optional)
5. Install sensors, valves, etc. per the instructions included with the items.
6. Install PWM valve assembly and feedback sensor for each control loop
and connect the devices to their respective inputs on the harness
making certain to match PWM 1/Servo 1 with FB1, PWM2/Servo 2 with
FB2, etc.
7. Secure any unused and excess cable lengths where necessary.
OUTPUT MODULE
The Output Module is an auxiliary to the Rate Control Module to drive
additional accessories installed on the vehicle such as boom section shutoff
valves, open and close V-Box gates, switching valves for front/rear
conveyors, switching valves for left/right discharge cross conveyors, and
accessory 12 volt switched output.
1. Select an area on the vehicle chassis to mount the module that allows
for easy hookup and access. Extensions may be used to reach
members installed on remote areas of the vehicle.
2. The module can be mounted in the same orientations as the rate
control module as illustrated in (Figure 7).
Flex4 ProTM Control System
6010541 Rev A
COMPONENT OVERVIEW / 11
OPERATOR’S MANUAL
Figure 8
Output Module
0.630
4.63
4.00
5.24
2.36
.291
2 HOLES
4.68
1.37
Do not install the module in any orientation other than illustrated
in (Figure 7). The connection wires must not be mounted upward
as moisture can collect inside the unit and damage the circuits.
Ensure that module connectors do not face upward.
3. Mount with the label side of the module facing out.
4. To bolt the member to a frame:
– Use the enclosure as a template to mark the location of the
mounting holes.
– Drill two 9/32 inch diameter holes where marked.
– Attach to frame using 1/4 x 20 bolts or other fastening devices as
illustrated in Figure 8.
Do not use the enclosure as a guide when drilling. Do not
overtighten nuts as this may damage the mounting tabs on the
enclosure.
12 / COMPONENT OVERVIEW
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
Figure 9
Securing Member with Bolts
TRUCK
FRAME
OR BED
SUPPORT
1/4 FLAT WASHER
1/4 x 20 BOLT
1/4 NUT
1/4 SPLIT
LOCKWASHER
TRUCK
FRAME
OR
BED SUPPORT
1/4 FLAT WASHER
1/4 x 20
THREADED "U"
BOLT OR
OTHER
FAS
TENING
DEVICE
1/4 NUT
1/4 SPLIT LOCKWASHER
5. To tie strap the module to a frame:
– Use one long tie strap to loop around the member body and
through both mounting holes as illustrated in Figure 9.
– If necessary, drill mounting holes following the procedure described
above.
– Securely tighten tie strap.
– Install a second tie strap toward the label end of the enclosure for
additional support.
Flex4 ProTM Control System
6010541 Rev A
COMPONENT OVERVIEW / 13
OPERATOR’S MANUAL
Figure 10
Securing Member with Tie Straps
TRUCK
FRAME
OR
BED
SUPPORT
6. Connect an output module harness to the output module and connect
the output module harness to the Power/CAN backbone, refer to
(Figure 16).
7. Connect each module harness to its module inserting both connectors
until the connector locking tabs engage.
8. Lay out the boom shutoff harness along the boom frame to each of the
shutoff outputs.
9. Route wires in locations where they will not be damaged.
10. Secure the harness with tie straps.
NOTE: The last module harness in the
system must have a CAN
terminator installed for proper
system operation.
IMPORTANT: Ensure the locking tabs engage when inserting the
connectors. The connection is sealed only when the
locking tabs are fully engaged.
ATTACHING THE PCECU IN THE CAB
The PCECU module is the power management source for the Flex4 Pro
Control System. The PCECU mounts inside the cab and attaches to the cab
harness.
Figure 11
PCECU
7.45” 7.0” 3.93” 6.80” 14 / COMPONENT OVERVIEW
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
1. The PCECU module is mounted in the cab and should be placed near
the Accessory Plate that contains the USB hub, PCAN adapter, and
DC-DC converter. Mounting location can be on the floor, cab back, or
center console.
– Verify that the cab harness reaches between the PCECU and the
Accessory Plate.
2. Use the enclosure as a template to mark the location of the mounting
holes.
3. Drill four 9/32 inch diameter holes where marked. (Do we provide the
hardware to mount)
4. Mount with the label side of module facing out. Do not mount with the
connector facing up (see Caution).
5. Connect the PCECU to the designated location on the cab harness.
Do not install the module in any orientation other than shown in
(Figure 7). The connection wires must not be mounted upward as
moisture can collect inside the unit and damage the circuits.
MISCELLANEOUS COMPONENTS
RAM TOUGH HUB
USB distribution point for the system. Provides connections to the
USB-CAN adapter, camera adapter, and the USB data port below the
Operator Switch Module.
USB CAN ADAPTER
Provides a communication bridge between the tablet and the CAN bus.
DC-DC CONVERTER
Provides regulated 5V power to the tablet.
KEYBOARD
A keyboard is required to program and calibrate the system. The keyboard
has been environmentally hardened for use in the ice control field. After
programming and calibration, the keyboard is disconnected and stored.
GROUND SPEED SENSOR
The ground speed sensor generates vehicle speed information for the
console. Sensor electrical pulses proportional to the vehicle ground speed
are vital to system operation because true vehicle ground speed is
necessary for accurate product application. The system can function with a
variety of electronic and mechanical speedometer sensors, such as hall
effect and reluctance sensors.
Flex4 ProTM Control System
6010541 Rev A
COMPONENT OVERVIEW / 15
OPERATOR’S MANUAL
ROAD TEMPERATURE ADAPTER (OPTIONAL)
Temperature sensors allow for direct readout of road temperature and
ambient air temperature.
FEEDBACK/APPLICATION RATE SENSOR (OPTIONAL)
Feedback sensors send product flow information to the console for accurate
product application. Both granular and spinner channels require pulsed
electrical sensors having an output proportional to the mechanism speed.
The liquid channel accepts either electrical-pulsed sensors or analog
sensors with outputs proportional to material flow (pulsed). A liquid
prewetting system only accepts pulsed feedback while higher capacity
anti-icing systems accept either pulsed or analog.
GATE HEIGHT SENSORS (OPTIONAL)
Measures gate height setting in inches and automatically adjusts conveyor
speed to compensate for gate height changes and maintain application
rate.
HYDRAULIC PRESSURE SENSORS (OPTIONAL)
Hydraulic pressure sensors measure the amount of down pressure applied
on the underbody scraper.
FLOW METERS
Flow meter measures the flow rate of material being applied.
VALVE CONTROL OUTPUT
Flex4 rate controllers control PWM hydraulic and Servo valve electric
motors that regulate material flow for accurate control of product application
rates. Granular and spinner channels regulate the hydraulic oil flow rate to a
motor. Liquid channels use various different configurations such as servo
ball valves and electric pumps.
HARNESSES
Harnesses are included that are required for communication between the
console and components. Optional extension harnesses are available for
the Rate Control Module harness and output module harness when
mounted in areas where additional harnessing is required. Electric motor
driver harness is also available.
HOPPER LEVEL SENSOR (OPTIONAL)
A hopper level sensor can be used to trigger an alarm when material falls
below the sensor mounting level.
VIDEO CAMERA (OPTIONAL)
Multiple cameras can be installed in order to monitor dispensed material or
provide aid in backing the vehicle.
16 / COMPONENT OVERVIEW
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
INSTALLATION
OPERATOR SWITCH MODULE MOUNTING
BRACKET
The Operator Switch Module Bracket attaches the Operator Switch Module
to the tablet and includes the following components:
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•
•
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Main switch module mounting bracket
3 Hex nuts
4 washers
3 nuts/3 washers
OPERATOR SWITCH MODULE BRACKET AND TABLET
MOUNTING PLATE
Attach Tablet Mounting Plate to the Operator Switch Module Bracket:
1. Remove the 4 screws from the back of the tablet plate
2. Align switch module bracket holes with the plate holes.
3. Secure the bracket and plate with the 4 screws.
Attach Switch Module to Operator Switch Module Bracket:
4. Align stud bolts (3) to the bracket opening and insert the switch
module.
5. Align switch module so the connectors insert through the module
bracket connector opening and the (3) switch module stud bolts insert
through the bolt holes of the bracket assembly.
6. Secure switch module to the bracket using (3) hex nuts and washers.
Flex4 ProTM Control System
6010541 Rev A
INSTALLATION / 17
OPERATOR’S MANUAL
Figure 12
Attaching Operator Switch Module Bracket and Tablet Mounting Plate
4 Align stud bolts (3) to bracket opening and Insert Switch Module Tablet Plate Switch Module Bracket Connector 5 opening 6 Hex Nut (3) Washer (4) Remove ball mount attachment 9 3 1 8 Attach ball mount to bracket with (4) screws Remove screws from plate 2 Align switch module bracket holes with plate holes and secure with (4) screws 7 10 RAM Mount Bracket Loosen wing bolt Position ball mount back to RAM Mount Bracket and tighten wing bolt RAM MOUNT BRACKET INSTALLATION
The RAM mount bracket secures the tablet to the vehicle dashboard or
other surface suitable for operator viewing using a RAM mount bracket.
•
•
Ball mount at top and bottom of bracket allows for orientation in many
different positions.
Wing bolt in middle of bracket tightens and secures the tablet to the
desired position.
Attaching RAM Mount Bracket to Truck Cab:
1. Secure bracket to truck cab using 4 SAE screws (included).
2. Insert ball mount into bracket assembly and tighten wing nut.
3. Adjust tablet for ideal viewing by loosening/tightening the wing nut.
18 / INSTALLATION
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
Figure 13
RAM Mount
Secure Ram mount bracket (4) SAE Screws Position tablet so that operator view is not obstructed and does
not interfere with driving/operation.
ATTACHING ACCESSORY PLATE TO CAB
The Accessory Plate contains the USB hub (RAM Tough Hub), DC-DC
converter, and the USB CAN adapter. This plate should be mounted near
the PCECU module.
Recommended mounting location is inside the cab on the floor, back of cab
wall, or center console. The Accessory Plate should be mounted in an area
that avoids possible moisture.
Refer to System Harness connection diagrams for attaching these
components to the cab harness.
Figure 14
Accessories Plate
DC Converter USB CAN Adapter RAM Tough Hub Flex4 ProTM Control System
6010541 Rev A
INSTALLATION / 19
OPERATOR’S MANUAL
SYSTEM HARNESS CONNECTIONS
The Flex4 ProTM control system connects to the truck cab harness and is
powered on and off when the ignition switch is powered on and off. The
Flex4 Pro tablet must be powered on after the ignition switch is powered on.
System harnessing connections include:
•
•
•
•
•
•
Cab harness
Rate control module harness
Optional output module harness
Optional extension harness
Optional electric motor/pump driver harness
Optional Road Watch adapter and Flex4 interface cable
Figure 15
System Architecture with Electric Motor / Pump Driver and Optional Output Module Harness
CAN Terminator Switch Module 466495210 Camera to Adaptor USB cable power adaptor 467985410S1 RAM Tough Hub USB Can Adaptor DC Converter Power connection to Video Camera Rate Control Module Harness 466495071 PC ECU Application Rate Hydraulic Valve Cab Power
Harness 6010766
Down Pressure Output module 466492101 Extension Harness 466495060 Rate Control Module Flow Meter Gate Height Ground Sensor Speed Control Valve Electric Motor/ Pump Driver 466495430 connects to Rate Control Module harness Output Module Harness 466495081 Boom Shutoff Valve Flex4 Interface Cable 466495072 Battery Temperature Sensor Road Watch Adapter 20 / INSTALLATION
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
Figure 16
System Architecture with Electric Motor/Pump Driver Harness
CAN Terminator Switch Module 466495210 RAM Tough Hub USB Can Adapter DC‐DC Converter Camera to Adaptor USB cable power adaptor Power connection to Video Camera PC ECU Rate Control Module 467985410S1 Rate Control Module Harness 466495071 Connects to Rate Control Electric Motor/ Module Harness Pump Driver 466495430 Extension Harness 466495060 Cab Power Harness 6010766
Application Rate Hydraulic Valve Flow
Meter Ground Speed Battery Control Valve Flex4 Interface Cable 466495072 Gate Height Sensor Temperature Sensor Road Watch Adapter Down Pressure Flex4 ProTM Control System
6010541 Rev A
INSTALLATION / 21
OPERATOR’S MANUAL
CAB HARNESS
NOTE: The ignition lead must be
connected to switched +12VDC
for the system to power up and
down properly.
1.
2.
3.
4.
Connect the power leads directly to the battery.
Connect the ignition wire to a switched +12VDC.
Connect the chassis ground lead to a direct battery ground connection.
Connect the micro USB cable from the tablet charging port to the DC/
DC adapter USB plug.
5. Connect the USB data cable to the mini USB port, upper right corner
labeled “USB IN” on the RAM tough hub.
Figure 17
NOTE: Please see Appendix C for a
full cab harness connection
layout.
RAM Tough-HUB Connections
mini USB connection Spade connection Connect to tablet using barrel jack connector and then plug USB male into cable coming out of the DC‐DC adapter (female USB) 6. Connect the PCECU to the cab harness.
7. Connect the CAN terminator, Operator Switch Module, and
RoadWatch to their respective connectors on the cab harness.
8. For an installed camera, attach the 12V power camera adapter to the
harness. Plug the adapter into the USB tough hub mounted to the
accessories plate.
Figure 18
Cab Harness
To Extension Harness or Rate Control Module Harness Ignition Power connection to video USB CAN camera Adapter PC ECU CAN Terminator Switch Module to battery RAM Mount DC‐DC Hub Converter 22 / INSTALLATION
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
RATE CONTROL MODULE HARNESS
1. Connect the Rate Control Module harness to the mating connector of
the cab harness (use an extension harness if additional length is
needed).
2. Secure harness as needed.
3. Connect the module harness to the mating connectors of the CAN/
power backbone, if used. The Rate Control Module uses a 30 and
18-way connector with a jackscrew to secure the connector to the
module. The output module uses a pair of 12-pin connectors.
4. Secure module harness as needed.
Figure 19
Rate Control Module Harness
Rate Control Module Cab or Extension Harness PWM Ch 4 Aux S/Spinner PWM Ch 3 Granular PWM Ch 2 Auxiliary PWM Ch 1 Liquid CH4 Spinner Feedback CH1 Liquid Feedback CH2 Auxiliary Feedback CH3 Granular Feedback Ground Speed Remote On/Off Joystick Scraper Servo 1 Liquid Electric Pump Driver Harness, Extension Harness, or Output Module Harness
Digital 1 Sensor Terminator Digital 2 Sensor Hopper Level Sensor Remote Blast Ch2 Pressure/Bed Height (Analog 1) Down Pressure Sensor (Analog 4) Gate Height Sensor (Analog 3) Flex4 Interface cable attaches to any of the analog 1‐4 connectors. RoadWatch Temperature Sensor Adapter connects to the Flex4 Interface cable. Tank Level Sensor (Analog 2) Boom Section Servo 2 Auxiliary Flex4 ProTM Control System
6010541 Rev A
INSTALLATION / 23
OPERATOR’S MANUAL
ROADWATCH TEMPERATURE ADAPTER AND FLEX4
INTERFACE CABLE
The Flex4 Interface cable connects to any of the Rate Control Module
Harness analog 1-4 connectors. The RoadWatch Temperature adapter
connects to the Flex4 Interface cable.
The analog position must then be identified at the (F9) Accessory Sensor
screen to identify what function is connected to the analog 1, 2, 3, or 4
connector.
Figure 20
RoadWatch Temperature adapter and Flex4 Interface Cable
Connects to Rate Control Module Harness via Analog 1, 2, 3, or 4 connectors Flex4 Interface Cable Temperature Sensor Road Watch Adapter EXTENSION HARNESS
Extension harness (10 ft) is optional and used when extra length is required
to connect with the Rate Control Module harness and the Output Module
harness.
Figure 21
Extension Harness
24 / INSTALLATION
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
OUTPUT MODULE HARNESS
Optional output harness controls boom section shutoff.
1. Connect the output harness to the mating connector of the Rate
Control Module harness.
2. Use extension harness, if required.
3. Connect output module and boom shutoff modules to the mating
connectors of the CAN/Power backbone.
4. Connect electric motor/pump driver harness, if used.
Figure 22
Output Module Harness
Output Module Electric Motor Pump Driver Harness Rate Control Module Harness or Extension Harness Output 1 Output 2 Boom Shutoff Valves Reverse Auger Conveyor Left Output 3 Conveyor Right Output 4 Output 5 Output 6 +12V Switch Out Gate Height ELECTRIC MOTOR DRIVER HARNESS
Drives electric pumps or motors that draw high current (greater than 2
amps).
Figure 23
Electric Motor Driver Harness
To electric pump
Rate Control Module Harness, Extension Harness, To PWM channel (liquid or auxiliary) Flex4 ProTM Control System
6010541 Rev A
INSTALLATION / 25
OPERATOR’S MANUAL
26 / INSTALLATION
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
OPERATE SCREEN OVERVIEW
The Flex4 ProTM tablet is powered on manually by pressing the Power button
located on the top right edge of the tablet next to the volume adjustment.
IMPORTANT: The ignition key should be powered on prior to the Flex4 Pro
tablet.
The Operate screen has five main structured areas to display button
selections and operation functions that include:
1. Control channel application rate windows displays up to 4 channels
when assigned as materials (non spinner)
2. Display function buttons on left and right side of display
3. Main operator window displaying alarms, temperature readings,
spread width status bar, and optional video
4. Accessory/alarm status windows
5. Ground speed, time, and date information
6. Battery status power bar and position indicator
NOTE: Large font on the Operate
screen indicates the control is
active. Small font indicates the
control is not active.
Figure 24
Operate Screen Layout
1 2 2 3 4 6 5 (1) CONTROL CHANNELS
Four control channels monitor granular and liquid applications and also
controls spinner speed.
Flex4 ProTM Control System
6010541 Rev A
OPERATE SCREEN OVERVIEW / 27
OPERATOR’S MANUAL
Control channel windows display target application rates (APR) when the
vehicle is stationary and the actual application rate when spreading material
for granular and liquid materials.
– Application of granular material (pounds/kilogram) per mile (km) or
area based (pounds per square foot or grams per square meter)
(lbs/acre)
– Application of liquid material gallons (liters) per ton based on the
granular applications rate or gallons (liters) per mile (km) and
gallons (liters) per square yard (meter) (gal/acre)
An auxiliary channel window allows selection of another granular or liquid
channel with the same units available as channel one and two.
Target rates of product control channels can be changed by pressing the
respective Rate Increase/Decrease button on the switch module. An
audible beep indicates a rate adjustment change.
Channels are turned on and off by pressing the respective CH ON or CH
OFF function buttons. The channel window reads “OFF” when the channel
is selected to be off and returns to the rate when turned on again. Channel
must be selected using spread width knob.
(2) DISPLAY FUNCTION BUTTONS
Twelve buttons are located on the left and right side of the tablet user
interface screen providing screen navigation and quick adjustment to
system settings.
NOTE: Interchange the Spread Width
Bar window with the Channel
(Rate) window by pressing the
screen and swiping to desired
location.
(3) SPREAD WIDTH BAR
Spread width bar indicates spinner operation and spread width in percent.
Value is adjusted using the spread width knob on the switch module.
Rotating the spread width knob on the switch module changes the rotational
speed of the spinner and indicates the percentage on the spread width bar
display. The bar is at the 100% position when the knob is clockwise
corresponding to maximum spinner speed. Pressing the spinner left and
right arrows positioned on the sides of the spread width bar indicates the
selected spinner to be changed. Both can be adjusted simultaneously.
(3) ROAD/AIR TEMPERATURE SENSORS
When enabled, the current road/air temperature displays on the Operate
screen with current readings and triggers an audible alarm when outside of
defined parameters.
(3) BOOM SECTIONS
Boom nozzle graphics appear on screen, when enabled, to indicate boom
section on/off status.
(3) CONVEYOR
When enabled, a left/right conveyor symbol and a front/rear conveyor
symbol provides current position and can be changed by pressing the
respective buttons.
28 / OPERATE SCREEN OVERVIEW
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
(3) ALARMS
Alarm text appears in this window when user-defined parameters are
outside of limits set.
(4) ACCESSORY SENSORS/ALARMS
•
•
Digital and analog accessory sensors enabled will display sensor
status in the lower display window.
Accessory alarms display in this area with a one beep audible alarm.
The sensor status remains in red until issue is resolved.
(5) GROUND SPEED/TIME/DATE/BATTERY INDICATOR
•
•
•
Ground speed is independent of product application and displays
actual ground speed in the lower display window. A manual ground
speed setting also appears in this location, when enabled.
Current time and date displays below the ground speed window.
Battery status bar indicates battery charge status. The system should
maintain a full charge in normal operating conditions. If the battery
discharges during normal operation, there could be an issue with the
system cabling or the DC-DC converter.
DISPLAY SETTINGS (CAMERA/DISPLAY/ALARMS)
Display settings adjust the characteristics of appearance and volume of the
tablet:
•
•
•
Camera settings (appearance of the camera window display on the
tablet)
Display brightness (lightness/darkness of screen)
Alarm volume (high/low adjustment of audible alarm when error
occurs)
To change a Display Setting:
1. At the Operate screen, press the Display Settings button.
2. To modify a display setting, press the Camera, Display Brightness, or
Alarm Volume button.
3. Press the Increase button or Decrease button to adjust the bar graph.
Each time the button is pressed the setting changes and is visible on
the screen with a percent adjustment.
NOTE: Pressing the Back button
returns to previous menu.
Camera settings, display brightness, and alarm volume values are adjusted
in bar graph form.
– The Camera Settings bar graph indicates the appearance of the
camera window on the display allowing adjustment to brightness,
contrast, saturation, hue, and rotation.
– The Display Brightness bar graph indicates the brightness level of
the display. A full bar graph indicates the most brightness. The
brightness changes each time the Increase/Decrease buttons are
pressed.
– The Alarm Volume bar graph indicates the volume level for the
audible alarm. An empty bar graph indicates the lowest volume;
Flex4 ProTM Control System
6010541 Rev A
OPERATE SCREEN OVERVIEW / 29
OPERATOR’S MANUAL
a full bar graph indicates the highest volume. The volume level will
sound each time the increase/decrease arrows are pressed.
Figure 25
Display Settings Screen
A B C Adjustment Buttons A Camera Window 1 6 2 7 Day/Night Mode 3
Adjustment 8 50% 9 A B 4 C 5 B 10 C 11 Current Display Settings DAY AND NIGHT MODE
Day and Night mode adjusts the tablet screen colors for better visibility to
sunlight or while operating at night. The default screen setting is night
mode.
To change Day/Night Mode:
1. Press the Day Mode On button (item 3) to change to the Day Mode
setting. Press again to return to the night mode setting.
Figure 26
Day and Night Mode Screens
Day Mode Night Mode 30 / OPERATE SCREEN OVERVIEW
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
OPERATION
The Flex 4 ProTM tablet is powered on manually by pressing the Power button
located on the top right edge of the tablet next to the volume adjustment.
IMPORTANT: The ignition key should be powered on prior to the Flex 4 Pro
tablet.
A DICKEY-john startup screen and Flex4 ProTM screen displays for a
minimum of 60 seconds before the Operate screen appears and the system
is operational.
The console automatically closes all system actuators and performs self
tests including system configuration and application data during startup. If
an error occurs at power up or during operation, an error message displays
with recovery information.
IMPORTANT: The system should be programmed and calibrated
before spreading material.
It is recommended to wait before powering on the Flex4 ProTM
tablet until temperature stabilization occurs between the tablet and
truck cab, especially when exposed to cold to hot temperature
extremes.
Cab temperatures should be above 32 degrees for proper
operation.
Humidity levels should be below 95% before powering on device.
Figure 27
Powerup Screens
Flex4 ProTM Control System
6010541 Rev A
OPERATION / 31
OPERATOR’S MANUAL
PRE-OPERATING CHECKLIST
The following procedures must be performed for effective operation:
•
•
•
•
Perform System Response procedure for all granular, liquid, and
auxiliary channels
Calibrate ground speed sensor
Enter material application rates for each product to be applied
Calibrate each material’s associated sensors at running conditions
(Spreader, K-Factor, Spinner, and Gate Height calibrations)
ADJUSTING OPERATE SCREEN LAYOUT
Moving the position of control channels and the spread width box on the
Operate screen is possible by touching within the box until the channel and
spread width boxes shift position.
Figure 28
Repositioning Channel and Spread Width
SPREADING MATERIAL
To Begin Spreading Material:
1. Press the Auto On/Off button to engage Automatic mode. AUTO
appears on the display when the system is stationary.
2. As the vehicle starts moving, AUTO is replaced with the material
application rate relative to the ground speed. When the vehicle stops,
material application will stop.
To Increase/Decrease a Rate:
1. Select the channel/material to change by pushing in the Spread Width
knob on the switch module. The selected channel is highlighted in
yellow.
2. With the selected channel highlighted, press either the Rate (-) or Rate
(+) until the desired rate displays.
32 / OPERATION
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
NOTE: System setup is only accessible
when the system is stationary
with no ground speed.
Figure 29
Operate Screen
RIVER OGIN SPINNER Auto enabled with 0 ground speed ANTI‐ICE DRIVER OGIN SPINNER ANTI‐ICE Application of material relative to ground speed NOTE: Application rate appears in
small font when the control is
not active. Rate appears in a
larger font when the control is
active.
BLAST
The Blast function is operable for both stationary and moving vehicle
conditions to increase the amount of material spread by a predefined rate.
Blast can be used in Auto mode, manual control channel override, and
manual ground speed.
To Activate Blast:
1. Press the Blast button. An alarm sounds indicating Blast is activated
and Blast appears on the display. A Blast rate automatically shuts off if
a time interval has been defined at the Blast Setup screen.
If a predefined time interval has been set to zero, Blast must be turned off
manually by pressing the Blast button again.
Flex4 ProTM Control System
6010541 Rev A
OPERATION / 33
OPERATOR’S MANUAL
Figure 30
Blast Feature Enabled
CH BLAST BLAST ROUTE SELECT RIVER OGIN SPINNER ANTI‐ICE PAUSE
The Pause feature stops applying material while operating in Auto mode but
continues to calculate miles driven. Pause can be used in Auto mode,
manual control channel override, and manual ground speed.
To activate Pause:
1. To enable, press the Pause button. An alarm sounds indicating Pause
is activated and Pause will appear on the display.
2. To disable, press the Pause button again. An alarm sounds indicating
Pause is disabled and will disappear on the display.
Figure 31
Pause Feature Enabled
CH ROUTE SELECT RIVER OGIN SPINNER ANTI‐ICE 34 / OPERATION
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
MATERIAL SELECTION
One granular, one liquid, and two auxiliary (liquid or granular) materials can
display simultaneously on the display.
To Change a Material:
1. With the vehicle stopped and ground speed at 0, press the Material
Select button.
2. At the Material Selection screen, press either the Granular or the
Liquid button.
3. Press the Select Arrow button to choose the desired material.
Selected material displays in yellow.
4. When selected, press the Back button to return to the Operate screen.
Figure 32
Material Selection
CH CH ROUTE SELECT DRIVER LOGIN USER SPINNER HELP ANTI‐ICE GRANULAR LIQUID AUX S Flex4 ProTM Control System
6010541 Rev A
OPERATION / 35
OPERATOR’S MANUAL
TURN OFF AN ACTIVE CHANNEL
A channel can be turned off while in Auto mode.
1. Push in the spreader width knob on the switch module to highlight the
desired channel/material. To select the liquid channel, an additional
press is required.
2. Press the CH OFF button. If a granular channel is turned off, any active
material spreading in gallons/ton will also turn off simultaneously. A
liquid channel can be independently turned off and the granular
channel will stay active.
3. Press the CH ON button to re-activate the channel.
Figure 33
Turning a Channel Off
CH OFF Liquid channel ROUTE SELECT DRIVER LOGIN SPINNER ANTI‐ICE CH ON OUTE SELECT DRIVER LOGIN SPINNER ANTI‐ICE UNLOAD MATERIAL
The Unload feature quickly removes remaining material from the vehicle.
Vehicle must be stationary for operation to begin.
To Unload Material:
1. Position vehicle to appropriate location with ground speed at 0.
2. At the Operate screen, press the Unload button.
3. At the Material Select screen, choose materials by pressing the
corresponding button. Selected materials for removal displays at
center of screen, i.e. “Salt Selected”.
4. Press the Start button to begin unload.
5. Press the Stop button when unload is complete.
36 / OPERATION
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
Figure 34
Unloading a Material
START X
X
STOP Ensure the area is clear prior to unloading to avoid possible injury.
Flex4 ProTM Control System
6010541 Rev A
OPERATION / 37
OPERATOR’S MANUAL
MANUAL GROUND SPEED OVERRIDE
Manual ground speed override is a manual override feature used when the
ground speed sensor has failed. A manual speed can be entered in setup
mode forcing the system to operate in manual speed mode and to spread
material at the specified rate.
To operate in Manual Override:
1. At the Operate screen, press the Material Select button.
2. At the Material Select screen, press the Manual Speed button.
Continue pressing the Manual Speed button until Enable Manual
Speed is highlighted.
3. Press the Select Arrow buttons to increase/decrease manual speed.
Figure 35
Manual Override
CH ROUTE SELECT SPINNER DRIVER LOGIN ANTI‐ICE O.O Increase/ decrease manual speed 4. Press the Back button to return to the Operate screen. Manual Speed
is now enabled and displays on the Operate screen.
When operating in manual mode, the system is turned on and off using the
Auto On/Off button.
IMPORTANT: The Pause button is functional in manual mode however
miles driven during Pause mode will not be added to
total miles driven while operating with manual ground
speed enabled.
38 / OPERATION
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
NOTE: If manual mode is not
accessible, manual speed
access has been set to off in
the program mode.
Figure 36
Operate Screen with Manual Mode Enabled
CH ROUTE SELECT DRIVER OGIN SPINNER ANTI‐ICE Manual Override Enabled AUTOMATIC MANUAL CONTROL CHANNEL
OVERRIDE
When an application rate sensor or flow meter failure occurs, the system
reverts to automatic manual override and continues to operate the control
channel in a manual override state. Manual override allows material to be
spread at the same programmed rate without interruption. When a failure
occurs, the rate decreases to “0” and “Manual” replaces the material name.
Rate returns from “0” back to target rate while manual override is enabled.
NOTE: Accuracy of material
application rates will be
affected due to the loss of a
rate feedback sensor.
Figure 37
Manual Control Channel Override
CH LOGIN MANUAL MANUAL 0.0 0.0 OUTE SELECT SPINNER SPINNER ANTI‐ICE ANTI‐ICE CH DRIVER LOGIN MANUAL MANUAL 550 13.0 OUTE SELECT SPINNER ANTI‐ICE Flex4 ProTM Control System
6010541 Rev A
OPERATION / 39
OPERATOR’S MANUAL
DRIVER LOGIN
The Driver Login screen displays a list of up to 20 drivers created by an
authorized user. The Driver Login screen automatically displays if a login is
required when the system is powered on. The Operate screen displays after
the passcode is entered.
NOTE: If it is important to log data by
driver, verify that the Driver
Login function is enabled at the
(F12) Data Logging screen.
To Login:
1. At the Driver Login screen, select the respective number for the driver
operating vehicle.
2. Enter the passcode for the driver.
– Press the Back button to correct an incorrect passcode entry.
3. Press the Enter button to accept the passcode and display the
Operate screen.
Figure 38
Driver Login Screen
To Logout:
1. At the Operate screen, press the Logout button. The driver is
automatically logged out and displays the Driver Login screen for the
next driver.
NOTE: If the Route Selection button
does not appear on the
Operate screen, it has not been
enabled at the (F12) Data
Logging screen.
NOTE: Miles, hours, and spread totals
are logged by route and
viewable at the Totals screen.
40 / OPERATION
ROUTE SELECTION
The Route Selection screen lists up to 20 routes created by an authorized
user in setup mode. A route can be selected from the list and will appear on
the Operate screen.
To Select a Route:
1. At the Operate screen, press the Route Select button to display the
Route Select screen.
2. Select the desired route by pressing the respective Route (1-20)
button. The only routes that appear are those created at the Data
Logging screen. Once the route is selected, the screen automatically
returns to the Operate screen with route name listed.
3. To remove the route from the Operate screen, return to the Route
Select screen and press the No Route button.
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
Figure 39
Route Selection Screen
BOOM SECTION CONTROL
Boom section control buttons appear on the Operate screen when ground
speed is greater than zero. Button state indicates action to occur when
pressed.
To enable Boom Section Control:
•
•
•
NOTE: Refer to page 66 to enable
boom section control feature.
Press the Section ON button(s) to turn on. When a section is turned
on, the button changes to a Section OFF button.
Each section can be turned on and off independently.
Spray nozzle graphics indicate active state. Any nozzle that is active
displays in green and a nozzle that is inactive displays in red.
Figure 40
Boom Section Control
Button indicates action to occur when pressed Flex4 ProTM Control System
6010541 Rev A
OPERATION / 41
OPERATOR’S MANUAL
ANTI-ICE FEATURE
An Anti-Ice button appears on the Operate screen when a channel is
enabled for anti-ice material. Activating the anti-ice feature automatically
turns granular and liquid channels off to spread anti-ice material.
Deactivating anti-ice stops spreading anti-ice material and automatically
turns the granular and liquid channels on again.
To activate Anti-Ice:
1. At the Operate screen, press the Anti-Ice On button.
2. Press the Anti-Ice Off button to deactivate.
IMPORTANT: To enable the Anti-Ice Button mode at the Operate
screen, refer to “System Programming Anti-Ice Button
Mode Feature” section for proper setup.
Figure 41
Anti-Ice On/Off Feature
Granular and Liquid channels are ON Anti‐Ice OFF Granular and Liquid channels are OFF Anti‐Ice ON ACCESSORY SENSORS
A dedicated accessory window at screen bottom of the Operate screen
displays the enabled accessory sensors. When operating within normal
ranges, the sensor status appears in green text. When the pre-defined
limits exceed the normal ranges, an audible alarm beeps with an alarm
message and the sensor status flashes in red. Operation can continue
when a sensor is in an alarm state and the sensor status remains in red until
normal ranges are met.
OUTPUT MODULE ACCESSORIES
An accessory connected to an output module and enabled at the (F11)
Output Module screen can be monitored and controlled at the Operate
screen.
Front/Rear Conveyor
•
42 / OPERATION
The Front/Rear Conveyor button toggles between front and rear
operation. A graphic indicates the current active state.
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
Figure 42
Front/Rear Conveyor Button and Graphics
REAR
Gate Increase/Decrease
•
•
If gate height is increased, the conveyor speed decreases.
If gate height is decreased, the conveyor speed increases.
Figure 43
Gate Increase/Decrease Buttons
Left/Right Spinner
•
Left/Right Spinner button toggles between activating the left spinner,
right spinner, or both left and right spinner.
Figure 44
Left/Right Spinner
LEFT
Flex4 ProTM Control System
6010541 Rev A
RIGHT
OPERATION / 43
OPERATOR’S MANUAL
HYDRAULIC ACCESSORY TOOL OPERATION
To control an accessory tool during operation, press the Rate Increase/
Decrease buttons on the Operator Switch Module to increase and decrease
the hydraulic flow. The PWM signal percentage sent to the hydraulic valve
displays in the channel window.
Accessory tools shut off when:
– Ground speed reaches zero
– or the Auto On/Off switch is turned off.
An increase in ground speed activates the tool to the previous PWM
percentage.
The control channel is set to Manual without Feedback for this feature.
Refer to Granular Configuration Setup (F2).
Figure 45
Operate Screen with Manual Percentage Reading
Control Channel Salt set for Manual w/o Feedback CURRENT AND SEASON RUN TOTALS
The Totals screen provides accumulated material usage, miles, and hours
driven using Auto mode, Blast, and Pause functions. Total operating data
can be viewed in current run totals, season run totals, or by route.
NOTE: Totals by driver are viewable
only by exporting the data file to
a report software tool program.
Run totals are logged and recorded in the following ways:
•
•
•
•
•
•
•
44 / OPERATION
Total Miles (km), tons (metric/English), and gallons (liters) spread while
in automatic control mode for each control channel and product
spread.
Miles (km), tons (metric/English), and gallons (liters) spread while in
Blast mode for each product spread.
Total vehicle miles (km) driven
Liquid gallons (liters) sprayed during prewetting and anti-icing
application
Total time spent spreading granular, spraying liquid, and blasting
Miles (km), tons (metric/English), and gallons (liters) spread while in
Pause mode
Trip Log indicates total miles driven in Operate mode
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
To view Totals:
At the Operate screen, press the Totals button.
1. Current, Season, and Route button toggles between Current,
Season, and Route run total screens.
2. Material Type Select button toggles between granular and liquid
materials.
3. Material Select button scrolls through and displays totals for each
material.
4. To reset totals, press the Reset Current Material button.
5. Reset Trip Log button clears accumulated miles to zero.
6. Route Select button toggles and displays totals for each route.
7. Back button returns to previous screen.
IMPORTANT: Season totals are cleared at the F12 Data Logging/
Operational Totals screen. Current and Route totals are
clearable at this screen, if the capability is enabled at
F12 Operational Totals.
Figure 46
Total Screen
1 4 5 2 3 6 7 Flex4 ProTM Control System
6010541 Rev A
OPERATION / 45
OPERATOR’S MANUAL
46 / OPERATION
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
FLEX4 PROTM PROGRAMMING
A keyboard is required to program and calibrate the system. The keyboard
is removed after programming is complete. System will not allow entry of
setup menus, calibration, or configuration without a keyboard attached.
IMPORTANT: After plugging in the keyboard, the Flex4 ProTM tablet
screen must be touched first before the keyboard
becomes active and usable.
Function keys (F1 through F12) located at the top of the keyboard are used
to display 12 menu screens that define desired system settings.
Configuration parameters can be changed on menu screens by using the
up and down arrow keys on the keyboard or by selecting the configuration
parameter by screen touch.
Access to menus using keyboard function keys include:
•
•
•
•
•
•
•
•
•
•
•
•
F1 Operate screen
F2 Granular Channel Setup
F3 Liquid Channel Setup
F4 Auxiliary S Granular/Liquid/Spinner Channel Setup
F5 Auxiliary Granular/Liquid Channel Setup
F6 Calibration
F7 Diagnostics
F8 Ground Speed Setup
F9 Accessory Sensor Setup
F10 System Setup
F11 Output Module Setup
F12 Data Logging
PASSCODE RESTRICTIONS
Two types of passcodes are optional and can be enabled to require a driver/
supervisor to:
•
•
Login with a passcode before driver operation is allowed
Login to gain access and change configuration setup values with a
keyboard
The system passcode settings are shipped as disabled. Passcodes can be
enabled at the (F10) System screen (Driver Login Setup).
Once passcode settings are enabled, the codes are required before a driver
begins operation or configuration setup screens are accessed. Passcodes
can be any combination of numbers up to 10 digits.
Flex4 ProTM Control System
6010541 Rev A
FLEX4 PROTM PROGRAMMING / 47
OPERATOR’S MANUAL
KEYBOARD FUNCTIONS
Programming is performed when the truck is stationary and the system is
off. Attach the keyboard to the USB port below the Operator Switch
Module.
KEYBOARD FUNCTIONS
(1) Function labels identify each function button
(2) Function button displays menus for respective functions
(3) Number buttons are used to select parameters from menu list and to
insert values
(4) Alpha buttons are used to create text labels and to make selections
(5) Enter button accepts an entry and opens a window for text fields if more
than one selection is available for a parameter
(6) Escape button returns to the previous menu
NOTE: A value on the screen is
selected by using the up/down
arrow keys on the keyboard to
highlight a function box or the
virtual keyboard.
Figure 47
Keyboard Layout and Functions
6 1 2 @ ! # $ % 3 4 1 5 2 3 OPERATE GRANULAR LIQUID
Esc F3 F1 F2 W Q AUX S
AUX
CAL.
F4 F5 E DIAG.
ACC.
SENSORS
^ 6 U Caps Lock A D F G H Ctrl X Alt C
~ V B N O 5 J M _ + = ‐ * P { 6 _ [ L K 1 Z Shift Fn S Num PrtSc Scroll Pause Lock SysRc Lock Break F11 F12 ( ) 9 9 0 I 4 4 F10 & * 7 7 8 8 Y OUTPUT
DATA
MODULE LOGGING
SYSTEM
F6 F7 F8 F9 T R GROUND
SPEED
2 : " Enter ? / / Ins Shift Home | \ Enter + 3 > < , 0 . Alt Back Space } ] 5 PgDn End Del ` TM
TEXT ENTRIES
1. Press Enter to open a text window on the screen to display all possible
selections.
2. Use the Up/Down Arrow buttons to highlight and select the desired
parameter.
3. Press Enter to accept.
48 / FLEX4 PROTM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
Figure 48
Open a Text Window
Press ‘Enter’ to open text window Flex4 ProTM Control System
6010541 Rev A
FLEX4 PROTM PROGRAMMING / 49
OPERATOR’S MANUAL
LABEL ENTRIES
1. To create label names, such as a Material Name, highlight the field and
begin typing the name. A virtual keyboard displays onscreen and the
name as entered appears at top of the virtual keyboard.
2. Press the Enter button to accept the label entry.
NOTE: The Enter button will not select
a text field.
Figure 49
Virtual Keyboard
Using the keyboard up/down arrow buttons select and highlight a parameter Material Label 50 / FLEX4 PROTM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
NUMBER ENTRIES
1. To enter a number value, highlight the field and begin typing numbers
from the keyboard. A virtual keypad display onscreen and the number,
as entered, appears at top of the virtual keypad.
2. Press the Enter button to accept the label entry.
Figure 50
Virtual Keypad
2500.0 Number Keypad Flex4 ProTM Control System
6010541 Rev A
FLEX4 PROTM PROGRAMMING / 51
OPERATOR’S MANUAL
52 / FLEX4 PROTM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
SYSTEM PROGRAMMING
The Flex4 ProTM Control system has configuration screens to enter
user-defined rates, limits, and parameters for regulating system product
application. A keyboard is required for programming.
NOTE: After plugging in the keyboard,
the Flex4 ProTM tablet screen
must be touched first before the
keyboard becomes active and
usable.
Four channels are available for material and spinner control:
•
•
•
•
(1) dedicated granular channel (F2)
(1) dedicated liquid channel (F3)
(1) auxiliary channel for granular/liquid or spinner control (F4)
(1) auxiliary channel for liquid or granular (F5)
Please read "Appendix A: Channel Linking Conditions and
Recommendations" prior to setting up your material application controls.
Additional setup for proper system operation includes performing:
•
•
•
•
•
•
•
System Calibration (F6)
Diagnostics (F7)
Ground Speed Setup (F8)
Accessory Sensor Setup (F9)
System Setup (F10)
Output Module Setup (F11)
Data Logging (F12)
IMPORTANT: System programming MUST be conducted before
performing a system calibration. Accurate system
calibration constants are determined through regular
calibration routines. Known constants can be entered
reducing the calibration procedures required.
Calibration corrections can be performed anytime to
fine-tune accuracy.
OPERATE MODE (F1)
The Operate screen can be accessed at any time during programming by
pressing the F1 function key. No programming functions are available at this
screen but can be used to verify active selections.
The Operate screen shows programmed values for spreading material and
provides access to the following functions:
•
•
•
•
Material Selection screen
Unloading Material screen
Tablet Display settings
Current Totals screen
Refer to the Operation section for detailed function descriptions.
ANTI-ICE BUTTON MODE FEATURE
A special mode is available in those situations where toggling
between turning on anti-ice and turning off liquid/granular happens
simultaneously by pressing an Anti-Ice button on the Operate screen.
Flex4 ProTM Control System
6010541 Rev A
SYSTEM PROGRAMMING / 53
OPERATOR’S MANUAL
To get the Anti-Ice button to appear on the Operate screen, the
following channels must be set per the following steps.
To Enable the Anti-Ice Button on the Operate screen:
1. Press the (F2) Granular button to verify the granular channel is
enabled.
2. Press the (F3) Liquid button and set the channel to prewet.
3. Press the (F5) Auxiliary button and set the channel to Anti-Ice.
4. Press the (F1) Operate button, the Anti-Ice button displays onscreen.
Figure 51
Activating the Anti-Ice Key
Granular and Liquid channels are ON Anti‐Ice OFF Granular and Liquid channels are OFF Anti‐Ice ON 54 / SYSTEM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
GRANULAR CHANNEL SETUP (F2)
Granular channel setup screen defines the set of values of four material
application rates, min/max limits, and blast rates as well as the configuration
parameters for hydraulic valves and sensors.
Granular channel parameters include:
•
•
•
•
•
•
Material Label
Units
Spreader Constant
Calibration Gate Height
Application Rate Method (Step or Rate)
Blast Rate
The channel’s current status displays as Enabled or Disabled.
To Change the Channel’s Status:
1. Use the Up or Down arrow keys on the keyboard to select and
highlight the function box.
2. Press the Enter key and select the desired function status as either
Enable or Disable.
3. Press the Enter key to accept.
4. To define material rates, press the respective item number (1 - 4) using
the keyboard to display the Granular Rates screen.
5. Press the Enter key to open a menu selection box to display and
select the appropriate parameters.
NOTE: Calibration Gate Height only
appears on this screen when
enabled and configured at the
Accessory Sensors (F9)
screen.
Figure 52
Granular Channel Setup
STEP METHOD RATE METHOD Flex4 ProTM Control System
6010541 Rev A
SYSTEM PROGRAMMING / 55
OPERATOR’S MANUAL
GRANULAR RATE SETUP
MATERIAL LABEL
A user-defined material name entered (10 characters maximum) that
identifies the material configured for a channel on the Operate screen.
UNITS
Unit of measure for granular material are available in the following
parameters:
–
–
–
–
–
–
lbs (kilograms) per mile (km)
lb/mi ft (g/km-m)
lbs per sq ft/grams per sq meter
lbs per sq yd/meter
lbs/kft2 (Kg/m2)
lbs per acre (Kg/Ha)
SPREADER CONSTANT
Represents the number of pulses generated by the application rate sensor
per pound of material (P/LB or P/KG) discharged from the spreader. The
spreader constant varies for each granular material, spreader vehicle, and
gate height setting (if optional gate height sensor is installed and enabled).
If the spreader constant is known, the value can be manually entered via a
keyboard with no granular calibration required. For unknown spreader
constant values, a granular calibration should be performed.
CALIBRATION GATE HEIGHT
Calibration Gate Height displays only if the gate height sensor is enabled at
the Accessory Sensor screen (F9). If enabled, the calibration gate height
value displayed is the setting of the gate height (inches) as a result of a
performed spreader calibration.
IMPORTANT: The Gate Height must be enabled before a spreader
calibration is performed. Refer to the Spreader
Calibration procedure.
The original calibrated gate setting can be changed to provide a more
accurate granular material application by adjusting the conveyor speed.
– An increased gate height decreases conveyor speed
– A decreased gate height increases conveyor speed
If the sensor voltage is outside the range between the Closed and Open
position values, the display states Gate Low or Gate High. If Gate Low
displays, the signal from the sensor is exceeding the open voltage. In either
case, an alarm activates. The Gate Height should be checked and set at
the granular calibration it was ran for on that granular channel.
56 / SYSTEM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
APPLICATION RATE METHOD
Two methods are available to control material application:
•
•
Step Method
Rate Method
Step Method
Allows rates to be changed by a fixed increment using the Rate Increase/
Decrease buttons on the switch module.
NOTE: Rate changes only occur when
the material is selected/
highlighted on the Operate
screen.
To select the Step Method:
Maximum Rate establishes the maximum application rate in lbs/mile or g/
Km-m that the control allows. Target Rate cannot be incremented to a value
greater than this established Max Rate.
1. Highlight the Step method selection box and press the Enter key on
the keyboard.
2. Select Yes and press the Enter key again.
3. Enter the desired target rate (lbs/mile) for material application to be
controlled by this channel.
4. Enter a minimum application rate limit for this channel. Minimum rate
establishes the minimum application rate that the control allows. Target
rate cannot be decremented to a value lower than this established Min
Rate.
5. Enter a maximum application rate limit for this channel. Maximum rate
establishes the maximum application rate that the control allows.
Target rate cannot be incremented to a value greater than this
established Max Rate.
6. Enter an Increase/Decrease Step value that sets the increase/
decrease rate. The increment/decrement percent rate establishes the
percentage of change of the entered target rate that is applied each
time the Rate Increase/Decrease button is pressed.
NOTE: The maximum or minimum
rates may not be reached if the
% increase or decrease, based
off the target rate, exceeds the
maximum or minimum rate
limits set.
Flex4 ProTM Control System
6010541 Rev A
7. Enter a desired blast rate that applies a higher-than-normal, spot
application when the Blast button is pressed during operation.
Figure 53
Step Method Screen
SYSTEM PROGRAMMING / 57
OPERATOR’S MANUAL
To select the Rate Method:
Rate Method allows ten user-defined application rates to be entered. Rates
can be adjusted during operation using the Rate Increase/Decrease
buttons on the switch module.
1. Highlight the Step method selection box and press the Enter key on
the keyboard.
2. Select No and press the Enter key again.
3. Enter desired rates (Rates 1-10). If less than 10 rates are desired,
enter a zero (0) for each rate following the last programmed rate. The
initial rate displayed during operation is Rate 1. Other rates are
selected by pressing the Rate Increase/Decrease button on the
switch module.
4. Enter a desired blast rate that applies a higher-than-normal, spot
application when the Blast button is pressed during operation.
Figure 54
Step Method Screen
BLAST RATE
A Blast Rate (lbs per mile) defines a higher than normal spot-application
rate that is applied when the Blast button is pressed. A time and speed to
simulate the length of time and ground speed to apply material when the
vehicle is stationary can be entered at the (F10) System Setup screen.
When the Blast Speed is set to zero, blasting cannot be initiated when the
vehicle is stopped.
58 / SYSTEM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
GRANULAR CONFIGURATION (F2)
Configuration parameters defined for each channel correlate with the types
of hydraulic valves and sensors installed and related performance
specifications. These values should not change unless system hardware is
modified or related calibration routines are performed.
IMPORTANT: A calibration should be performed for each channel
prior to operating to ensure accurate material
application.
To enter Configuration Values:
1. At the F2 Granular Setup screen, press 5 on the keyboard.
2. At the Granular Configuration screen, highlight the control mode
selection box and press the Enter key to select Auto or Manual with
Feedback.
3. Press the Enter key to confirm the selection.
4. Use the keyboard arrow keys to scroll to each constant’s selection box.
Figure 55
Granular Configuration Screen
CONTROL MODE
MANUAL WITH FEEDBACK
Overrides the current system when not operating properly. Using the Rate
Increase/Decrease buttons during operation sets the RPM rate for the
control channel. Actual RPM rate displays based on actual ground speed
and spreader constants entered.
MANUAL WITHOUT FEEDBACK
Typically used when operating with an accessory tool, such as a front
sweeper, using a PWM signal to open and close the valve. The Increase/
Decrease buttons are used to increase/decrease the hydraulic flow to the
accessory tool and a PWM percentage on the Operate screen indicates the
PWM signal sent to the hydraulic valve.
Flex4 ProTM Control System
6010541 Rev A
SYSTEM PROGRAMMING / 59
OPERATOR’S MANUAL
AUTO
Control channel calculates application rates based on ground speed and
signal feedback from the application rate sensor (closed loop control) under
normal operating conditions.
DRIVE FREQUENCY
Drive Frequency specifies the frequency for the proportional valve. The
recommended setting is defined by the specific valve manufacturer.
PWM OFFSET
PWM Offset identifies the minimum amount of PWM valve drive required to
start the granular mechanism.
PWM SATURATION
PWM Saturation identifies the amount of drive the granular valve system
requires to operate a PWM valve at full speed.
SYSTEM RESPONSE
Adjusts the control system response time to the hydraulic and mechanical
systems of the granular control channel on each particular spreader vehicle.
VALVE BOOST
Increases the amount of system response initially applied to the granular
control to reach final operating speed as quickly as possible.
AFILT
Filters the feedback signal to minimize the effect of electrical noise and
mechanical vibrations. The smaller the number, the greater degree of
filtering.
MATERIAL
Selection of the four materials that are configurable for the channel.
SENSOR CONSTANT
Sensor Constant establishes the number of pulses for one revolution of the
application rate sensor. If a standard DICKEY-john application rate sensor is
used, the value should be set to 360.0.
SPREADER CONSTANT
The Spreader Constant displayed value is viewable only and indicates the
current setting. This value automatically adjusts when a granular calibration
is performed.
60 / SYSTEM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
CALIBRATION GATE HEIGHT
Calibration Gate Height only displays if enabled as an accessory sensor at
the (F9) Accessory Sensor screen. This value is viewable only and
indicates the current setting. The value automatically adjusts when a
granular calibration is performed.
Flex4 ProTM Control System
6010541 Rev A
SYSTEM PROGRAMMING / 61
OPERATOR’S MANUAL
LIQUID CHANNEL SETUP (F3)
Liquid channel setup allows configuration of up to four different liquid
materials, entry of the material parameters, and to identify the performance
specifications of the installed actuators and sensors. Each material can be
set with different parameters.
The liquid channel can be set as either Prewet (gal/ton) (spraying with a
pre-wet spray bar), Anti-ice (gal/mile) (used with anti-icing boom), or Liquid
(gal/area).
Liquid channel parameters include:
•
•
•
•
•
Material Label
Units
K Factor
Application Rate Method (Step or Rate)
Blast Rate
The channel’s current status is displayed as Enabled or Disabled.
To Change the Channel’s Status Function:
1. Use the Up or Down Arrow keys on the keyboard to select and
highlight the Function box.
2. Press the Enter key and select the desired function status as either
Prewet, Liquid, or Disable.
3. Press the Enter key to accept.
4. To setup material parameters for Materials 5-8, select items 1-4 using
the keyboard.
Figure 56
Liquid Channel Setup Screen
Boom selection only displays when a channel is set for liquid or anti‐ice application. LIQ 1 LIQ 2 LIQ 3 LIQ 4 62 / SYSTEM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
LIQUID RATE SETUP
Each material assigned to the liquid channel requires entry of material
parameters.
Figure 57
Liquid Application
LIQ 1 gal/ac 20.6 gal/ac 0.825 gal/ac 42.1 gal/ac 0.825 gal/ac 57.8 gal/ac ANTI‐ICE RATES A‐ICE 1 gal/mile PREWET 1 PREWET 1 gal/ton 29981.75 5.00 gal/ton 0.500 gal/ton 25.5 gal/ton 0.500 gal/ton 50.0 gal/ton Flex4 ProTM Control System
6010541 Rev A
SYSTEM PROGRAMMING / 63
OPERATOR’S MANUAL
MATERIAL LABEL
A user-defined material name entered (10 characters maximum) that
identifies the material configured for a channel on the Operate screen.
UNITS
The unit type selected displays material application rate as follows:
gal/mile - Gallons per mile
gal/mift - Foot traveled per mile
gal/ft2 -
Square feet per gallon
gal/yd2 - Square yards per gallon
gal/kft2 - Thousand square feet
gal/ac -
Gallons per acre
K FACTOR
K Factor represents the number of flow meter pulses generated by the
sensor per gallon/liter of dispersed liquid for pre-wet and anti-icing liquids
through the flow meter.
The K Factor number stamped on the flow meter body is sufficiently
accurate for keyboard entry if the viscosity of the liquid is near that of water.
If the flow meter constant is unknown, the actual value will adjust to the
correct constant during the liquid calibration.
APPLICATION RATE METHOD
Two methods are available to control the application of material:
•
•
STEP Method
Rate Method
STEP Method
STEP Method allows rates to be changed by a fixed increment using the
Rate Increase/Decrease buttons on the switch module. STEP method
requires a Target Rate, Min/Max Rate, and Inc/Dec Step defined.
To select the STEP Method:
Maximum Rate establishes the maximum application rate in gallons per
mile (L/km) that the control will allow. Target Rate cannot be incremented to
a value greater than this established Max Rate.
1. Highlight the Step method selection box and press the Enter key on
the keyboard.
2. Select Yes and press the Enter key again.
3. Enter the desired target rate for material application to be controlled by
this channel.
4. Enter a minimum application rate limit for this channel.
5. Enter a maximum application rate limit for this channel.
6. Enter an Increase/Decrease Step value that sets the increase/
decrease rate.
64 / SYSTEM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
IMPORTANT: The maximum or minimum rates may not be reached if
the % increase or decrease, based off the target rate,
exceeds the maximum or minimum rate limits set.
7. Enter a desired blast rate that applies a higher-than-normal, spot
application when the Blast button is pressed during operation.
Figure 58
STEP Method Enabled
TARGET RATE
Target rate establishes the desired amount of material to be applied in
gallons/mile by a control channel.
MINIMUM/MAXIMUM RATE
The minimum and maximum rates establish the minimum and maximum
application rates that the control will allow. Target rate cannot be
decremented to a value lower than this established minimum and maximum
rates.
INC/DEC STEP
The increment/decrement rate establishes the amount of change of the
entered target rate that is applied each time the Rate Increase/Decrease
button is pressed.
BLAST RATE
Blast Rate defines a higher than normal, spot-application rate applied when
the Blast button is pressed.
Rate Method:
Rate Method allows ten user-defined application rates to be entered. Rates
can be adjusted during operation using the Rate Increase/Decrease
buttons on the switch module.
To select the Rate Method:
1. Highlight the Step method selection box and press the Enter key on
the keyboard.
2. Select No and press the Enter key again.
Flex4 ProTM Control System
6010541 Rev A
SYSTEM PROGRAMMING / 65
OPERATOR’S MANUAL
3. Enter desired rates (Rates 1-10). If less than 10 rates are desired,
enter a zero (0) for each rate following the last programmed rate. The
initial rate displayed during operation is Rate 1. Other rates are
selected by pressing the Rate Increase/Decrease button on the
switch module.
4. Enter a desired blast rate that applies a higher-than-normal, spot
application when the Blast button is pressed during operation.
Figure 59
Rate Method Enabled
BOOM CONFIGURATION (LIQUID/ANTI-ICE)
Boom Configuration screen identifies how the unit is controlling or
monitoring boom sections and assigns boom sections to a liquid or auxiliary
channel. A total of 6 boom sections can be controlled by the system. A
DICKEY-john output module must be installed to support boom control.
To assign Boom Sections:
1. At the (F3) Liquid Menu screen, select 6 on the keyboard to display
the Boom Configuration screen.
1. Select the function type as either Control or Sense.
2. Select the active level output signal as either Ground or 12V.
3. To change the default name for each boom label, press the respective
number (1-6) and type the new label name in the virtual keypad.
4. Add the width of each boom section.
5. Select the channel type that controls each boom label.
66 / SYSTEM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
NOTE: Anti-ice and pre-wet channel
types do not require a width
entry and the width column will
not appear in those instances.
Figure 60
Boom Configuration Screen
FUNCTION
NOTE: Contact DICKEY-john Technical
Support at 1-800-637-3302 to
order a DICKEY-john output
module.
Control
Boom sections are controlled by a DICKEY-john output module allowing
sections to be turned on and off at the Operate screen with assigned
section buttons.
Sense
Boom sections are controlled by a separate switch box. Boom sections are
only sensed by the unit and displays on or off status on the Operate screen.
ACTIVE LEVEL
Active level sets the output signal as either ground or 12V for a valve driver
to control a boom shutoff delay.
Flex4 ProTM Control System
6010541 Rev A
SYSTEM PROGRAMMING / 67
OPERATOR’S MANUAL
AUXILIARY S (F4)
The Auxiliary control channel has programming flexibility as a Liquid,
Granular, Prewet, Anti-Ice channel or for spinner control.
Four materials are possible and assigned as materials 9-12.
Configuration and boom setup for an auxiliary channel must be enabled at
this screen for the channel to be in an active state. Refer to the Granular
Configuration (F2) and Liquid Configuration (F3) sections for parameter
definition and setup instructions.
Refer to Assign ‘Auxiliary S’ as Spinner to configure channel for spinner
control.
Press the Calibration (F6) key to initiate channel calibration.
Figure 61
Aux S Screen
ASSIGN ‘AUXILIARY S’ AS SPINNER
Spinner constants set the parameters and performance specifications for
installed actuators and sensors. These values do not change unless the
system hardware changes or the related calibration routines are re-run.
To enter Spinner Configuration Values:
1. At the F4 Aux S screen, use the Up or Down Arrow keys on the
keyboard to select and highlight ”Spinner”.
2. Press “1” to enter parameter values per below definition.
68 / SYSTEM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
Figure 62
Spinner Configuration Screen
SPINNER UNITS
Spinner units set the spread width bar graph to display in percent, feet, or
RPM. Pulse Feedback must be set to YES for the spinner units to be
selected as RPM. If a spinner spread width calibration is required, spinner
units must be selected as feet to perform the calibration.
UNLOAD
Enable the Unload feature by selecting Yes to activate the spinner during
unloading. Select No to disable during the unload process.
DRIVE FREQUENCY
Drive Frequency specifies the frequency for the installed proportional valve.
The recommended setting for this option should be specified from the valve
manufacturer.
NO GROUND SPEED
Select Yes to allow the spinner to continue running when there is no ground
speed. Select No for the spinner to stop running when there is no ground
speed.
BLAST RATE
A Blast Rate percentage greater than zero percent sets the maximum
spinner speed when Blast is pressed regardless of any adjustment to the
spread width knob. A Blast Rate percentage set at zero places no
constraints on the maximum spinner speed when using the spread width
knob.
Flex4 ProTM Control System
6010541 Rev A
SYSTEM PROGRAMMING / 69
OPERATOR’S MANUAL
PULSE FEEDBACK
Enable Pulse Feedback by selecting YES for closed-loop control. Disable
Pulse Feedback by selecting NO for open-loop control.
SPINNER CONSTANT
Establishes the number of pulses for one revolution of the spinner. Spinner
Constant appears only when Pulse Feedback is YES.
PWM OFFSET
Identifies the minimum amount of PWM valve drive required to start the
liquid mechanism.
PWM SATURATION
Identifies the amount of drive the liquid valve system requires to operate a
PWM valve at full speed.
SYSTEM RESPONSE
Adjusts the control system response time to the hydraulic and mechanical
systems of the liquid control channel on each particular spreader vehicle.
VALVE BOOST
Increases the amount of system response initially applied to the liquid
control to reach final operating speed as quickly as possible.
AFILT
Filters the feedback signal to minimize the effect of electrical noise and
mechanical vibrations. The smaller the number the greater degree of
filtering.
GROUND SPEED RELATED (GSRS)
Regulates the spinner speed related to ground speed and running closed
loop. Enable by selecting Yes. Controlling the spinner according to ground
speed allows the material to disperse at zero velocity. Displays only if Pulse
Feedback is YES.
GSRS SLOPE
When GSRS is enabled, GSRS Slope indicates the spinner revolutions per
mph/kmh on the Operate screen. Displays only if Ground Speed Related is
YES.
MAXIMUM GSRS
When GSRS is enabled, Max GSRS determines the scaling of the spinner
bar graph on the Operate screen. A full bar graph indicates that the
maximum GSRS speed has been exceeded in mph/kph. No alarm is
associated with this constant. Displays only if Ground Speed Related is
YES.
70 / SYSTEM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
AUXILIARY CONTROL CHANNEL
CONFIGURATION (F5)
The Auxiliary control channel has the flexibility to be programmed as a
Liquid, Granular, Prewet, or Anti-Ice channel with the same parameter
setup available as channels one and two.
Four materials are possible and assigned as materials 5-8.
Configuration and boom setup for an auxiliary channel must be enabled at
this screen for the channel to be in an active state. Refer to the Granular
Configuration (F2) and Liquid Configuration (F3) sections for parameter
definition and setup instructions.
Press the Calibration (F6) key to initiate channel calibration.
Figure 63
Auxiliary Control Channel Screen
Flex4 ProTM Control System
6010541 Rev A
SYSTEM PROGRAMMING / 71
OPERATOR’S MANUAL
ACCESSORY SENSORS (F9)
Accessory sensor screen sets the parameters for installed sensors that can
be monitored, when enabled, on the Operate screen. All accessory sensors
are set to disabled and must be enabled and may require calibration.
Up to four analog sensors can be enabled at one time. Analog sensor types
include:
•
•
•
•
•
Gate height
Bed height
Road/Air temperature (requires the Flex4 interface cable and
RoadWatch temperature adapter that connects to any of the analog
1-4 positions on the rate control module harness.
Tank level
Down pressure
Two digital accessory sensors can be enabled at one time.
In addition to configuring accessory sensors, an installed DICKEY-john
joystick’s active position can be viewed on the Operate screen when
enabled at this screen.
To enable Accessory Sensors:
1. At the (F9) Accessory menu screen, highlight the Analog Acc Sensor
input box and press the Enter key to open the sensor drop down list.
2. Select the sensor and press Enter.
3. To open the Sensor Configuration screen of the selected sensor, press
the corresponding key (1 - 6) to select a menu item. Refer to
(Figure 64).
IMPORTANT: The RoadWatch Sensor adapter must be connected to
an additional adapter cable that connects to the Rate
Control Module harness. The adapter cable must be
connected to the connectors labeled as Analog 1, 2, 3 or
4 . The connection point for the road temperature and air
temperature must be identified at the F9 Accessory
Sensor screen.
Figure 64
Accessory Sensors Screen
Press 1‐7 on keyboard to enable and configure respective sensors. 72 / SYSTEM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
GATE HEIGHT SENSOR
A gate height sensor compensates for changes from the original calibrated
gate setting by adjusting the conveyor speed for a more accurate granular
material application. If the gate height is increased, conveyor speed
decreases and a decreased gate height increases the conveyor speed.
Gate Height status appears on the Operate screen as GATE 0.0 IN (cm).
Figure 65
Gate Height Sensor
PRESS C TO CAPTURE VOLTAGE GATE HEIGHT CALIBRATION
Gate height calibration captures the voltage range of seven gate height
positions from the closed to open positions that are used when spreading
material.
To perform a Gate Height Calibration:
1.
2.
3.
4.
Select YES to enable gate height.
Highlight the Closed Inches (cm) column.
Set the gate to the closed position.
Measure the height at the closed position and enter that amount in
inches (cm) in the Closed input field.
5. Press “C” to capture the current gate height voltage at the closed
setting. The voltage automatically is calculated and entered at each
position.
6. Repeat steps 3 through 5 for each position. The gate should be at the
full open height to measure at the Open position.
If the sensor voltage is outside the range between the closed and open
position values, the display will state Gate Low or Gate High and an alarm
activates. The gate height should be checked and set at the granular
calibration it was ran for on that granular channel.
If the gate height is enabled and calibrated, all of the desired granular
materials that are enabled must be recalibrated through a material drop
test. If enabled materials are not calibrated, the system will alarm.
Flex4 ProTM Control System
6010541 Rev A
SYSTEM PROGRAMMING / 73
OPERATOR’S MANUAL
ROAD TEMPERATURE SENSOR
A road temperature sensor monitors road temperature changes. When
enabled, an alarm on the Operate screen identifies when defined road
temperature changes occur.
IMPORTANT: The RoadWatch Sensor adapter must be connected to
the Flex4 Interface cable that connects to the Rate
Control Module harness. The Interface cable must be
connected to the connectors labeled as Analog 1, 2, 3 or
4. The connection point for the road temperature and air
temperature must be identified at the F9 Accessory
Sensor screen.
Road Temperature status appears on Operate screen as:
67F ROAD TEMPERATURE AIR 75F To enable Road Temperature Values:
1. At the Road/Air Temperature Menu screen, select the corresponding
number.
2. Select Yes at the Temperature Enabled input box.
3. Enter the alarm temperature in degrees F to alert of road temperature
changes to indicate when application rate or material changes are
required. Temperatures must be entered in descending order with
Alarm Temp 1 the highest setting and Alarm Temp 3 the lowest setting.
4. Enter the temperature hysteresis that will clear the temperature alarm
when a positive temperature change has occurred. If Alarm Temp 1 is
20 degrees F and the Temperature Hysteresis is set at 5 degrees F, the
alarm activates when the temperature drops below 20 degrees F and
clears when the temperature reaches 25 degrees F.
5. The High and Low Calibration values should not be changed and
should be created from the calibration routine.
6. After values are entered, press C to begin the calibration procedure.
Calibration lasts approximately 10-20 seconds.
7. Press “D” when done.
74 / SYSTEM PROGRAMMING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
Figure 66
Road Temperature Sensor
IMPORTANT: The Road WatchTM temperature sensor or Surface
PatrolTM temperature sensor must be disconnected and
the Flex4 Interface cable and the DICKEY-john
temperature sensor adapter connected to the main
harness for successful calibration. If the interface cable
and the DICKEY-john temperature sensor adapter is
disconnected when the calibration is performed, an
error screen displays.
NOTE: Road WatchTM is a registered
trademark of Commercial
Vehicle Group TM. Surface
Patrol Technology is a
registered trademark of Control
Products Inc.
Flex4 ProTM Control System
6010541 Rev A
Figure 67
Road Temperature Sensor Calibration
SYSTEM PROGRAMMING / 75
OPERATOR’S MANUAL
AIR TEMPERATURE SENSOR
An air temperature sensor monitors air temperature changes. When
enabled, an alarm on the Operate screen identifies when defined air
temperature changes occur. Refer to Road Temperature section for display
appearance on Operate screen.
To enable Air Temperature Sensor Values:
1. Air temperature sensor input values and calibration procedures are
similar to road temperature sensors. Refer to Road Temperature
Sensor section for entering values.
NOTE: The Road WatchTM
temperature sensor or Surface
PatrolTM temperature sensor
must be disconnected and the
DICKEY-john temperature
sensor adapter connected to
the main harness for successful
calibration. If the DICKEY-john
temperature sensor adapter is
disconnected when calibration
is performed, an error screen
displays.
Figure 68
Air Temperature Sensor Screens
IMPORTANT: The Road WatchTM sensor adapter must be connected to
the Flex4 interface cable that connects to the rate
control module harness. The interface cable must be
connected to the rate control module connectors labeled
as Analog 1, 2, 3 or 4. The connection point for the road
temperature and air temperature must be identified at
the F9 Accessory Sensor screen.
76 / SYSTEM PROGRAMMING
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6010541 Rev A
OPERATOR’S MANUAL
TANK LEVEL SENSOR CONFIGURATION
The tank level sensor monitors the liquid level for pre-wet or anti-ice
systems.
To enable the Tank Level Sensor:
1. At the Tank Level Menu screen, select Yes at the Tank Level Enabled
input box.
2. Tank level status can display in a bargraph format (Yes) or percentage
of approximate material remaining (No).
3. Highlight the Empty Voltage input box. The tank must be empty before
performing the Empty Voltage calibration.
4. Press “C” to capture the empty voltage reading.
5. Fill tank to appropriate level. Highlight the Full Voltage input box. The
tank must be full before performing the Full Voltage calibration.
6. Press “C” to capture the full voltage reading.
IMPORTANT: It is recommended that voltages are automatically
captured but manual entry of voltages can be entered.
7. Enter a tank level alarm percentage to warn when the tank level has
reached the alarm limit. The value has a 5% hysteresis tolerance to
prevent random alarming due to varying tank levels while driving.
EXAMPLE: If the tank alarm is set for 10%, the alarm activates
when the level drops below 10% but will not clear until the level
reaches 15%. If the tank alarm is set for 100 gallons on a 1000
gallon capacity, the alarm activates when the level drops below 100
gallons but does not clear until the level reaches 150 gallons.
The alarm sounds for the first five seconds and text will flash until
the condition is cleared or another alarm sounds.
Figure 69
Tank Level Sensor
PRESS C TO CAPTURE VOLTAGE Flex4 ProTM Control System
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DOWN PRESSURE
A down pressure sensor monitors the relative pressure applied to the under
body belly scraper.
Down Pressure status appears on the Operate screen as:
DWN PRES100% To enable the Down Pressure Sensor:
1. At the Down Pressure Menu screen, select Yes at the Down Pressure
Enabled input box.
2. Highlight the Minimum Pressure input box.
3. Elevate the scraper before performing the minimum pressure reading
calibration.
4. Press “C” to capture the minimum pressure reading.
5. Highlight the maximum pressure input box.
6. Position the scraper downward until road contact occurs and the
desired normal road contact pressure is reached. This will set the
100% down pressure maximum value (next step).
7. Press “C” to capture the maximum voltage reading.
IMPORTANT: It is recommended that voltages are automatically
captured through the calibration but manual entry of
voltages can be entered.
8. Enter a down pressure alarm percentage to warn when the down
pressure is within the specified percentage of reaching the maximum
down pressure limit.
Figure 70
Down Pressure
78 / SYSTEM PROGRAMMING
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BED HEIGHT
A bed height sensor activates when the bed has exceeded the
recommended operating height.
All mechanical linkages should be inspected and maintained on a
regularly scheduled interval to ensure proper operation of the bed
height alarm. Visual inspection of the bed height must be
maintained as the primary indicator of safe bed height operation.
The alarm should only be used as a secondary convenience
indicator. The operator assumes all risk in using this feature.
DICKEY-john assumes no responsibility for alarm failure to
indicate an unsafe operating height.
Bed Height status appears on Operate screen as:
BED 113% To enable a Bed Height Sensor:
1. At the Bed Height Menu screen, select Yes at the Bed Height Enabled
input box.
2. Highlight the Bed Down input box. The dump bed must be completely
down and the sensor installed before performing the calibration.
3. Press “C” to capture the bed down reading.
4. Bed Alarm indicates the voltage when the bed has exceeded normal
operating height and can be entered manually or automatically.
5. Highlight the Bed Alarm input box. The dump bed must must be near
the maximum operating height and the sensor installed before
automatic entry can occur. Press “C” to automatically capture sensor
voltage. For manual entry, select the bed alarm text and enter the
voltage when the bed exceeds the normal operating height.
Figure 71
Bed Height Sensor Screen
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OPERATOR’S MANUAL
DIGITAL ACCESSORIES
Two digital sensors can be installed to monitor critical operation parameters
on the vehicle.
To enable a Digital Accessory Sensor:
1. At the F9 Accessory screen, press 6 or 7 to open a Digital Accessory
screen.
2. Select Yes at the Digital Acc Enabled input box.
3. At the Sensor Type input box, select the appropriate sensor as digital,
frequency, or camera. Sensor type determines what parameters
appear on the screen.
4. Select the Active Level power supply as either 12V or ground.
5. Enter an appropriate active and inactive label that identifies the sensor
type and status on the Operate screen.
6. Select the Alarm Mode as either Never, Auto, or Always.
Figure 72
Digital Accessory Screens
SENSOR TYPE
DIGITAL and FREQUENCY - Select the sensor type as digital or frequency.
CAMERA - Select camera to automatically view camera video on the
display screen when it senses a 12V input. Typically used when the truck is
placed in reverse and 12V is sensed; the camera automatically appears on
the display.
ACTIVE LEVEL (Digital or Camera)
Active level sets the sensor output signal as either Ground or 12V to sense
the sensor as on or off.
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ACTIVE LABEL
A user-defined name that identifies the sensor type or function that displays
on the Operate screen providing sensor status, i.e. active label name
(HOPPER FULL).
INACTIVE LABEL
A user-defined name that identifies the sensor type or function that displays
on the Operate screen providing sensor status, i.e., inactive label name
(HOPPER LOW).
ALARM MODE
NEVER - Alarms are turned off and will not trigger an alarm condition during
operation.
AUTO - Alarm occurs after the defined alarm delay only when the system is
active and controlling.
ALWAYS - Alarm occurs after the defined alarm delay during operate mode
and shutdown mode.
ALARM DELAY
Amount of time delay in seconds that occurs before an alarm is triggered
based on user-defined sensor parameters.
SYSTEM SHUTDOWN
Select Enabled to shutdown the system from operating anytime an alarm is
triggered.
Figure 73
Accessory Sensor Screen (Frequency)
LABEL (Frequency)
A user-defined name that identifies sensor type and displays on the
Operate screen providing sensor status (7 character maximum).
CONSTANT (Frequency)
Constant establishes the number of pulses for one revolution of the
application rate sensor.
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OPERATOR’S MANUAL
OFFSET (Frequency)
The Offset determines the units of which the constant is converting the
frequency into.
ALARM MODE
NEVER - Alarms are turned off and will not trigger an alarm condition during
operation.
AUTO - Alarm occurs after the defined alarm delay only when the system is
active and controlling.
ALWAYS - Alarm occurs after the defined alarm delay during operate mode
and shutdown mode.
HIGH/LOW ALARM LIMIT (Frequency)
The High and Low Alarm limit values determine when an alarm is triggered
to warn when a certain condition is met that is set by user-defined
parameters.
ALARM DELAY
Amount of time delay in seconds that occurs before an alarm is triggered
based on user-defined sensor parameters.
HIGH/LOW SHUTDOWN (Frequency)
The system shutdowns automatically when High and Low Shutdown is
enabled and the alarm condition is met as defined in High and Low Alarm
Limits. Both High and Low Shutdown functionality is independent of each
other.
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JOYSTICK LABELS
When a DICKEY-john joystick is installed, joystick labels can be created to
indicate functions that are enabled or active.
Joystick function appears on Operate screen as:
SCRAPER To create Joystick Control Names:
1. At the (F9) Accessory menu screen, press 7 on the keyboard to display
the Joystick Labels screen.
1. Select Yes at the Joystick Sense Enabled input box to indicate a
DICKEY-john joystick is installed.
2. At each label input box, enter a user-defined name that correlates with
the joystick function.
Figure 74
Joystick Labels Screen
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SYSTEM SETUP (F10)
System setup defines the following parameters:
•
•
•
•
•
•
Blast Setup
Date and Time
Units and Language
Service
Troubleshooting
GPS Sensor
To access the System Setup Screen:
1. Press the F10 key to display the System menu screen.
2. At the System Setup screen, press the respective item number to open
a menu item.
Figure 75
System Setup Screen
BLAST SETUP
1. Press 1 on the keyboard to select Blast Setup.
Figure 76
Blast Setup Screen
84 / SYSTEM PROGRAMMING
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OPERATOR’S MANUAL
BLAST TIMER
Enter number of seconds for the length of the Blast cycle. When set to zero
(0), the blast cycle lasts only as long as the Blast button is pressed.
BLAST SPEED
Establishes an artificial vehicle ground speed when vehicle is at a standstill
or moving slowly to compute the rate material dispenses during a blast
cycle.
– For speeds faster than this value, the actual vehicle ground speed
determines the spread rate.
– If Blast speed is set to zero, the screen will show a BLAST but no
material falls.
DATE AND TIME
The date and time of the unit is factory set to Central Standard Time. The
time can be re-set to the appropriate time zone by entering in either 12 hour
or 24 hour time.
To set Date and Time:
1. At the F10 System menu screen, press the 2 key to display the Date
and Time screen.
2. Select ‘Yes’ in the 24 Hour input box for a 24 hour clock setting. Select
‘No’ in the 24 Hour input box for a 12 hour (am/pm) setting.
3. At the Current Time input box, highlight the digits to change and type in
the time.
4. At the Current Date input box, highlight the digits to change and type in
the date.
Figure 77
Date and Time Screen
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UNITS AND LANGUAGE
The system is equipped with a set of various languages that display the
user screens in the language selected. Language default is English (US).
Available Languages:
•
•
English
Additional languages may be available on future releases. Contact
Technical Support at 1-800-637-3302 for available languages.
Units of measurement available:
•
•
US
Metric
To enter Units and Language:
1. At the (F10) System menu screen, press the 3 key to display the Units
and Language screen.
2. Select Yes to enable metric as the unit of measurement. Default is set
to English.
3. The current language setting of English cannot be adjusted.
Figure 78
Units and Language Screen
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SERVICE
The Service menu is typically used by authorized personnel to incorporate
product enhancements, troubleshoot, and identify the system’s current
software version.
1. At the (F10) System Menu screen, press 4 on the keyboard to select
the Service menu screen.
SOFTWARE VERSION
1. Press 1 at the Service screen to display the system’s installed software
version.
Figure 79
Software Version Screen
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OPERATOR’S MANUAL
SYSTEM RESET
1. Press 2 at the Service menu screen to reset system parameters to
default factory values.
2. A confirmation screen prompts a Yes or No selection before the system
reset occurs.
Figure 80
System Reset Screen
SERVICE KEYBOARD MODE
1. Press 3 at the Service menu screen to enable service keyboard mode
that allows keyboard use when the ground speed is above 0 AND the
ground speed is OFF.
High-level users have the ability to change the keyboard menu settings
while the master switch state is off without having to pull over to the side of
the road. This mode alerts with a periodic warning message on the Main
Work screen informing the that this mode is on and it should be turned off
during regular operation.
Figure 81
Service Keyboard Mode Screen
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TROUBLESHOOTING
Troubleshooting screens provide access to System Response screens
relating to spinner and material channels.
IMPORTANT: It is recommended that these parameters not be
modified as any changes could affect performance.
Contact DICKEY-john Technical Support at
1-800-637-3302 for assistance.
1. At the (F10) System menu screen, press 5 on the keyboard to display
the Troubleshooting screen.
2. Select the corresponding number to view the material or spinner
channel system parameters.
Figure 82
Troubleshooting Screen
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OPERATOR’S MANUAL
GPS SENSOR
If a GPS sensor is installed, it must be enabled at the GPS Sensor screen.
GPS coordinates with a time and date recording of the following events are
stored in the tablet:
•
•
•
•
•
•
When truck was started and turned off, type of material spread, and
application rates selected by operator
When control system was operating in an error condition, such as
application error, manual override, or loss of feedback sensor
When the control system exceeded the vehicle maximum speed alarm
set point
When control was in automatic mode of control versus off
When blast and pause function was activated
GPS coordinates of location by time and date
Log GPS Position per Event
This feature must be enabled to log events with GPS position and
coordinates in the data log file. GPS coordinates are stored in the log data
file for use in an data management software reporting package for vehicle
tracking.
If this feature is disabled, a sequence of events, miles driven, distance, and
speed are recorded with no GPS coordinates.
To enable GPS Sensor:
1. At the (F10) System menu screen, press 6 on the keyboard to display
the GPS Sensor screen.
2. Select Yes to indicate a GPS sensor is installed.
3. Select Yes to log GPS position and coordinates by event.
Figure 83
GPS Sensor Screen
90 / SYSTEM PROGRAMMING
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OUTPUT MODULE SETUP (F11)
An optional output module connects to the master control module via a CAN
BUS to control additional installed accessories. A 10 foot accessory
harness extension is available that connects the output module harness to
the rate control harness, if required.
Accessory functions include:
•
•
•
•
Boom section shutoff valves
Open and close V-Box gates
Switching valves for front/rear conveyors
Switching valves for left/right discharge cross conveyors
To enter Output Module Setup:
1.
2.
3.
4.
5.
Press F11 to display the Output Module screen.
Select Yes to Enable.
Select Yes if a 12V output signal is used.
Select Yes to control the front and rear conveyor.
Select Yes to control material application from the left and right side of
the truck at the Operate screen
6. Select Yes to control raising and lowering the gate height from the cab.
7. Enter the increase/decrease PWM% that determines how fast the gate
opens and closes.
8. Enter the increase/decrease time that affects the speed of opening and
closing the gate.
Figure 84
Output Module Setup Screen
FRONT/REAR CONVEYOR
Select Yes to control the front and rear conveyor position during operation
by selecting the front and rear conveyor buttons available on the Operate
screen. Current conveyor position is displayed on the Operate screen.
LEFT/RIGHT CONVEYOR
Select Yes to control material application from the left and right side of the
truck at the Operate screen. Spinner direction can be left, right, or both can
be on at the same time. The active position of the conveyor displays on the
Operate screen.
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OPERATOR’S MANUAL
GATE HEIGHT CONTROL
Select Yes to control raising and lowering the gate height from the cab.
INC/DEC PWM
The PWM percentage entered determines the PWM signal level that is sent
to the electric actuated cylinder when the gate increase or decrease button
is pressed from the main Flex4 ProTM tablet Operate screen. The higher the
PWM signal is set, the faster the gate opens or closes.
INC/DEC TIME
The time entered determines how long the PWM signal is sent to the
electric actuated signal each time the gate increase or decrease button is
pressed from the Flex4 ProTM tablet Operate screen. The higher the time is
set, the longer the gate continues to open or close upon a single press of
the gate increase/decrease button.
Example: PWM percentage set at 40 and time set at 2 seconds. Pressing
the Gate Increase button sends a 40% PWM signal to the electric actuated
cylinder for 2 seconds.
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DATA LOGGING (F12)
The Data Logging menu screen includes those items that are stored to data
files for transfer to a reporting software.
To view Data Logging Screens:
1. Press F12 to display the Data Logging menu screen.
2. Press the respective item number to open a menu item.
Figure 85
Data Logging Screen
ALARM HISTORY
Various alarm conditions can occur whenever the system encounters an
abnormal condition or detects a specific alarm. Alarms are presented in
either a full screen display or as an audible alarm. Full screen alarms
provide an alarm description and may give instructions on how to resolve
the issue. Each alarm type has an associated alarm number that can be
cross-referenced in the Troubleshooting and Alarms section.
Some alarms require a specific action before the alarm condition will cease.
In these cases, instructions are indicated on the alarm display.
Alarms can be acknowledged by pressing the Alarm Cancel button.
To view Alarm History:
1. At the Data Logging screen, press 1 to access the Alarm History
screen.
– The number of the alarm, data, time the condition occurred, along
with the alarm description displays.
– Up to 275 alarms can be recalled.
– Each alarm occurrence can have up to 6 occurrences of the alarm
tagged with a date and time stamp.
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OPERATOR’S MANUAL
NOTE: Press the Page Up or Page
Down buttons to view screen 2
alarms.
Figure 86
Alarm History Screen
TRUCK ID
An identifying name for a truck which can be changed at anytime. A Truck
ID is used as part of the file name during import/export of configuration and
data downloading to correlate the truck with the appropriate data files.
1. At the Data Logging screen, press 2 to access the Truck ID screen and
enter desired ID.
Figure 87
Truck ID Screen
94 / SYSTEM PROGRAMMING
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OPERATOR’S MANUAL
DRIVER SETUP
Driver logins require a passcode to perform certain system functions.
1. Driver ID Configuration (tracking of routes/roads/driver)
2. Configuration Setup (entry of configuration settings)
To customize Driver Details:
1. At the Data Logging screen, press 3 to display the Driver Details
screen.
2. At the Driver Details screen, press the corresponding number to
display the desired configuration screen.
Figure 88
Driver Details Screen
DRIVER ID CONFIGURATION
A driver login and passcode can be enabled to allow each driver to login
and logout when the unit is powered on or when users change so that
tracking of routes and roads with materials spread, miles driven, and route
spread can be recorded for an individual driver. The default language is
English but a specific language can be chosen so that during logon the
system automatically changes to the user-defined language for the driver.
Up to 20 different driver names and passcodes can be entered. An
additional screen to add names and passcodes is selected by pressing the
More button.
IMPORTANT: If a driver login on power up is mandatory, make sure to
select Configuration Setup at the Driver Details screen
(Figure 88) and set Driver Login Required as YES. If
Driver Login is set at NO and a driver passcode is
entered at the Driver ID Configuration screen, login is
available but will not automatically display on power up.
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OPERATOR’S MANUAL
To enable a Driver Passcode:
1. At the Driver Details screen, press 1 to display the Driver ID
Configuration screen.
2. Highlight the Driver Name input box and type in a user name.
3. At the passcode input box, enter a passcode for each user. To ensure
that individual driver’s data is recorded separately a different passcode
should be used for each driver name.
4. Select the appropriate language, if available.
– To remove a driver’s name and passcode, highlight the
corresponding delete input box located next to the user.
– Use the + or - key to enter a checkmark to select. Upon exit of this
screen, the selected driver and passcode will be removed.
Figure 89
Driver ID Configuration and Login Screen
After Driver ID Configuration is setup, the Driver Login/Logout screen
appears requiring the driver’s personal passcode before gaining access to
the Operate screen. Refer to the Operation section for additional
information.
96 / SYSTEM PROGRAMMING
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OPERATOR’S MANUAL
CONFIGURATION SETUP
NOTE: A keyboard is required to enter
configuration setup screens.
Enabling the Configuration Passcode will require a user to enter a passcode
independent of the driver ID passcode to enter, view, or change any of the
Configuration Setup screens.
Setting a passcode at the Configuration Setup screen restricts system
settings to only be changed by authorized users with the created passcode.
Once a passcode is enabled, it must be entered to gain entry into the
configuration screens.
NOTE: The unit is shipped with driver
and system passcode settings
disabled.
To modify Configuration Setup:
NOTE: Passcodes can only be entered
as numbers not as alpha
characters or symbols.
Figure 90
1. At the Driver Details screen, press 2 to display the Configuration Setup
screen.
2. Highlight the Configuration Passcode input box and select Enabled.
3. At the Passcode input box, enter a passcode using numbers only. A
passcode can be entered at this screen or by an attached keyboard.
4. Retype the passcode again in the Confirm Passcode input box.
5. At the Driver Login Required input box, select YES to require a driver
to enter a driver passcode as well as the system configuration
passcode. Select NO if a driver login personal passcode is not required
and only the configuration passcode is desired.
Configuration Setup and Configuration Passcode Screens
1 7 2 ENTER CONFIGURATION PASSCODE DATA
8 3 IMPORT
DONE
9 YOU MUST REBOOT THE TERMINAL TO SAVE ALL IMPORTED DATA ENTER REBOOT TERMINAL 4 0 5 6 BACK
After a configuration passcode is created, the Configuration Passcode
screen appears to gain entry into any configuration setup screens.
Returning to the Operate screen completes that setup session and requires
re-entry of the passcode again to enter setup screens.
Disabling the passcode setting resets the system allowing full access to
configuration screens.
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OPERATOR’S MANUAL
ROUTE CONFIGURATION
Twenty (20) pre-defined route names can be entered for selection on the
Operate screen so that data specific to that route; rates, material, total
quantity, miles driven, etc., is logged and recorded. Route specific data
can also be viewed at the Operational Totals screen.
To enter Route Names:
1. At the Data Logging screen, press 4 to access the Route Configuration
screen.
2. Highlight the Route Name input box and type in the desired name. A
maximum of 12 digits is accepted.
– To remove a route name, highlight the corresponding delete input
box located next to the user. Use the + or - key to enter a
checkmark to select. Upon exit of this screen, the selected route
will be removed.
After Routes are setup, a Route button is enabled at the Operate screen to
access the Route Selection screen. Refer to the Operation section for
additional information.
Figure 91
Route Configuration and Selection Screens
98 / SYSTEM PROGRAMMING
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OPERATOR’S MANUAL
OPERATIONAL TOTALS
Granular and liquid totals are logged individually and viewable on the Totals
screen by:
•
•
•
Current run totals
Season totals
Route
To view Operational Totals:
1. At the (F12) Data Logging screen, press 5 to access the Operational
Totals menu screen.
2. At the Operational Totals screen-Reset Totals Enable selection, select
Yes for operator access to clear totals from the Operate screen. Select
No for no operator access to clear totals. The Trip Log on the Totals
screen can be cleared with a Yes or No selection.
3. Select the corresponding number key to view granular, liquid, anti-ice,
prewet, or active material totals. Active Materials screen displays and
clears only the current materials displayed on the Operate screen.
– Press More button to view additional materials.
4. At the Material menu screen, select the corresponding number key to
view material totals.
5. At the Totals screen, press C to clear current totals and S to clear
season totals.
Material totals are reported in tons, miles, and hours for current and season
totals for the following modes:
AUTOMATIC MODE- total miles driven is logged in miles (km), tons (metric/
English), and gallons (liters) for each control channel and product spread.
BLAST MODE- total miles driven in Blast mode is logged in miles (km), tons
(metric/English) and gallons (liters) spread for each product.
PAUSE MODE- total miles driven in Pause mode is logged in miles (km),
tons (metric/English), and gallons (liters) spread for each product.
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NOTE: Season totals can only be
cleared using the keyboard at
the Operational Totals screen.
100 / SYSTEM PROGRAMMING
Figure 92
Operational Totals Screen
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6010541 Rev A
OPERATOR’S MANUAL
LIFETIME TOTALS
Accumulated totals display in miles and hours for Automatic, Blast, and
Pause modes. These totals are informational only and cannot be changed
or cleared.
To view Lifetime Totals:
1. At the (F12) Data Logging screen, press 6 on the keyboard to access
the Lifetime Totals screen.
Figure 93
Lifetime Totals Screen
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CALIBRATIONS
Spreader trucks have a variety of material delivery systems and various
combinations of hydraulic/liquid pumps, valves, and motors. It is important
that calibrations of the system and control channels are performed to define
configuration characteristics and ensure optimum performance.
Two calibration types are recommended prior to operation:
1. Material and Spinner System Response Calibrations
2. Drop Test Calibration
IMPORTANT: Performing the following procedures in the order
outlined ensures the greatest accuracy.
MATERIAL AND SPINNER SYSTEM RESPONSE
CALIBRATIONS (F6)
A system response calibration adjusts the response time of the system to
the installed hydraulic and mechanical systems. Performing this calibration
determines the system response and related constants, such as Valve
Boost, PWM Offset, and AFILT, for each of the control channels.
Constants may vary slightly each time a system response calibration is
performed. Manual fine tuning for optimum performance is acceptable.
IMPORTANT: During calibrations, the truck must be running and the
RPM’s should be within the truck’s normal operating
range.
GRANULAR RESPONSE CALIBRATION
During calibration, a set of values for System Response, Valve Boost, PWM
Offset, and AFILT automatically calculate, store, and display on the
Granular Configuration screens for all granular materials.
NOTE: Liquid pre-wet and liquid
anti-ice channel setup follows
same steps as granular. Refer
to page 105 for Drop Test and
Calibration procedures.
Flex4 ProTM Control System
6010541 Rev A
To perform a Granular System Response Calibration:
1. At the System Calibration screen (F6), select (1) Granular System
Response. A warning screen indicates this test activates the channel
and material will dispense.
2. Press “R” to begin test. A series of steps display on the screen during
calculations. When finished, the System Response Done screen
displays.
3. When the calibration is complete the results automatically record in the
proper locations. Press “C” to automatically begin drop test or press
“D” to return to the Calibration screen.
CALIBRATIONS / 103
OPERATOR’S MANUAL
Figure 94
System Response Calibration Screens
NOTE: Liquid pre-wet and anti-ice
channels have similar
calibration steps as granular.
104 / CALIBRATIONS
RECORDING CALIBRATION DATA
After performing each calibration, record the calibration constants on the
Calibration Data Record sheets included with this manual. If console
replacement is necessary, export system files to a USB memory device for
import to another system.
Flex4 ProTM Control System
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OPERATOR’S MANUAL
MAINTAINING CALIBRATION ACCURACY
Calibration accuracy can be affected by various conditions and to retain
optimum performance a system calibration should be performed for the
following conditions:
•
•
•
•
•
•
If a new material is added and the spreader, nozzle, or flow meter
constant is not accurately known, perform a granular or liquid
calibration routine.
If wear of the conveyor/auger mechanism, actuator valves, flow meter,
nozzles, or other system components is suspected, perform a new
catch test (granular or liquid calibration) to re-establish APR accuracy.
Perform a ground speed calibration after installing new or different
tires.
Each known physical (mechanical) change in the system should be
followed immediately by a system response calibration on the related
control channel (granular, liquid pre-wet, liquid anti-ice, or spinner).
A periodic system recalibration when repair or replacement has
occurred on any system components, including hydraulic hoses, fluid
changes, and normal wear.
A yearly system calibration of all control channels at the beginning of
each spreader season.
SYSTEM RESPONSE ADJUSTMENTS
Adjustments after a system calibration can be made so the system
responds faster or slower than calculated by the automatic calibration
routines.
Automatic calibration routines should always be performed prior
to modification to establish basic values.
System performance can be improved by adjusting the following functions:
SYSTEM RESPONSE CONSTANT
•
•
Control system responds slowly in speed and is slow to start
– Increase the system response value
System oscillates around the target APR
– Decrease the system response value
Excessive oscillation should be limited to +/-5% of the target APR to
minimize wear on the PWM valve. Most systems can be tuned by altering
only this value.
VALVE BOOST
Valve Boost increases system response only at startup to quickly start
system spreading. The value does not affect stability when operating at the
target APR and does not normally require adjustment.
Flex4 ProTM Control System
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CALIBRATIONS / 105
OPERATOR’S MANUAL
AFILT
Noisy feedback sensors cause the APR’s to randomly jump. AFILT value
indicates the amount of feedback noise rejection. The smaller the number,
the greater the filtering. Decreasing the AFILT can reduce the problem but
also can cause the system to become more sluggish. Typically this value
does not require adjustment.
GRANULAR DROP TEST CALIBRATION
The Drop Test determines the spreader constant for a given granular
material. The spreader constant is the number of pulses generated by the
application rate sensor per pound of granular material discharged. A
separate calibration routine must be run for each granular material used.
During a calibration the control system runs the conveyor/auger mechanism
dispensing material while the vehicle is stationary. When a sufficient amount
of material has been discharged, the operator stops the spreader
mechanism, weighs the material discharged, and enters the amount at the
Calibration screen. The system then calculates, stores, and displays the
spreader constant.
DROP TEST PREPARATION
1. Load the vehicle hopper with the desired material and verify the gate
height is adjusted to the proper setting on the V-Box spreader. If
tailgate spreads are in use, ensure auger is full.
2. Load enough material to provide a uniform flow throughout the
calibration procedure.
3. Position a suitable container or drop cloth to catch all dispensed
material from the conveyor/auger. The container must be large enough
to obtain a good, representative sample. The larger the sample
weighed, the better the accuracy. Alternatively, if a vehicle scale is
available, weigh the truck before and after dispensing material.
4. System is ready for calibration drop test.
PERFORMING A GRANULAR DROP TEST
NOTE: Steps 1 and 2 are performed
when a granular drop test is
initiated from the F6 Calibration
screen.
1. At the System Calibration screen (F6), select the Granular Drop Test
and follow the onscreen instructions.
2. At the Granular Calibration screen, select and press the corresponding
number (1-4) of the appropriate material.
A warning message indicates material will dispense when the
procedure is started. Ensure all personnel are clear before starting
the next step.
IMPORTANT: If a gate height sensor is installed, verify the gate height
sensor selection is enabled at the (F9) Accessory
Sensor screen before performing the drop test.
106 / CALIBRATIONS
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
NOTE: Calibration Data Sheets are
available in back of this manual
to record constants.
Flex4 ProTM Control System
6010541 Rev A
3. With the vehicle stationary, engage the hydraulic system.
4. Increase engine RPMs to normal operating range.
5. Press “R” to begin test and to run the conveyor/auger. Several steps
display during calculations before the System Response Done screen
appears. The number in the middle of the screen shows the counts
accumulating from the APR sensor. If a count is not recorded and
stays on “0”, stop the test and check the application rate sensor.
6. When a sufficient amount of material has dispensed, press “S” to stop
the system. A screen appears indicating the previous spreader
constant and the sensor counts accumulated during the current run.
7. Perform the next step while the screen waits for the results.
8. If using a vehicle scale, reweigh the truck and calculate the amount of
material dispensed in pounds.
9. Enter that number into the console and press “D” when finished. The
new spreader constant is now stored and displayed on the calibration
screen and on the appropriate configuration screen for this material.
10. For maximum accuracy, repeat the entire procedure at least three
times.
11. Average the results and enter the average as the final spreader
constant.
12. Record the material’s spreader constants on the Calibration Data
Records sheets at the rear of this manual.
13. Repeat this procedure for each granular material used.
CALIBRATIONS / 107
OPERATOR’S MANUAL
Figure 95
Granular Drop Test Procedure
108 / CALIBRATIONS
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
NOTE: Pressing “S” stops the
calibration and values default to
the original settings.
GRANULAR CALIBRATION ADJUSTMENTS
If small but consistent application rate errors are observed over a period of
time, the spreader constant can be modified to improve application
accuracy. Refer to Appendix A for steps to re-calculate a new spreader
constant. This constant can be manually entered on the Granular
Configuration screen. A granular calibration routine can also be repeated to
correct this type of APR error.
LIQUID DROP TEST CALIBRATION (F6)
A Liquid Drop Test Calibration determines a flow meter constant (K Factor)
for each liquid material used. The K Factor represents the number of pulses
generated by the flow meter per gallon of liquid dispensed. The nozzle
constant is a measure of flow rate through the nozzle at a standard
pressure. Separate calibrations are necessary for each liquid material
because of viscosity differences.
The liquid drop test routine causes the control system to run the liquid pump
dispensing material while the vehicle is stationary. When a sufficient amount
of liquid has been discharged, the system is stopped and the discharged
liquid weighed, and the amount entered at the Calibration screen. The
system then calculates, stores, and displays the K Factor.
DROP TEST PREPARATION
1. Load vehicle tank with material.
2. Position a suitable container to catch all the material dispensed
through the liquid pump. The container must be large enough to obtain
a good, representative sample. The larger the sample weighed, the
higher degree of accuracy. When calibrating a pre-wet liquid material,
the pre-wet bar can be removed from its mounting and placed inside
the catch container. Alternatively, especially for flow meter and anti-ice
liquid materials, temporarily disconnect an appropriate hose and place
inside the catch container.
3. System is ready for calibration drop test.
4.
NOTE: Calibration Data Sheets are
available in back of this manual
to record constants.
A warning message indicates material will dispense when
procedure is started. Ensure all personnel are clear before
starting the next step.
PERFORMING A LIQUID DROP TEST
NOTE: Steps 1 and 2 are performed
when a granular drop test is
initiated from the F6 Calibration
screen.
Flex4 ProTM Control System
6010541 Rev A
1. At the System Calibration screen (F6), select the Liquid Drop Test and
follow the onscreen instructions.
2. At the Liquid Calibration screen, select and press the corresponding
number (1-4) of the appropriate material.
– For pressure-based anti-ice systems, a target pressure must be
entered. This should be the nozzle manufacturer’s rating pressure
typically 40 psi (2.75 bar).
– If running pressure, ensure booms are drained prior to running
Offset
CALIBRATIONS / 109
OPERATOR’S MANUAL
A warning message displays indicating that material will dispense
when channel is activated. Ensure all personnel are clear before
starting the next step.
3. When ONLY the liquid channel is propelled by the hydraulic system,
start the engine keeping the vehicle stationary.
4. Engage the hydraulic system and increase the engine RPMs to normal
operating range.
5. Press “R” to run the liquid pump and start the calibration routine. For
flow meter based systems, use the Rate Increase/Decrease
buttons on the switch module to obtain an adequate discharge
rate. The number displayed indicates the accumulating count from the
APR sensor.
6. When a sufficient amount of liquid has dispensed, press “S” to stop.
– For a flow meter-based system, a screen appears showing the
previous K Factor and the sensor counts accumulated during the
current run.
– For a pressure-based system, the previous nozzle constant and
collection time display. The screen asks for an entry of gallons
before proceeding.
7. Perform the next step while the screen waits for the results.
8. Weigh the material caught and calculate the amount dispensed in
gallons.
9. Enter the number into the console and press Enter.
IMPORTANT: The amount dispensed value must be entered to adjust
the K Factor value; otherwise the K Factor will remain at
the current setting.
10. Press “D” when finished. The flow meter constant is now stored and
displayed on this screen and on the Liquid Configuration screen for this
material.
11. For maximum accuracy, repeat the entire procedure at least three
times.
12. Average the results and enter the average as the final K Factor
constant.
13. Record the material’s K Factor constants on the Calibration Data
Records sheets at the rear of this manual.
14. Repeat this procedure for each liquid material used.
110 / CALIBRATIONS
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
Figure 96
Liquid Drop Test Calibration Procedure
LIQUID CALIBRATION ADJUSTMENTS
If small but consistent application rate errors are observed, the values can
be manually adjusted to improve application accuracy. Refer to Appendix A
for steps to re-calculate a new flow meter constant. This constant can be
manually entered on the Liquid Configuration screen. A liquid calibration
routine can also be repeated to correct this type of APR error.
Flex4 ProTM Control System
6010541 Rev A
CALIBRATIONS / 111
OPERATOR’S MANUAL
AUXILIARY SYSTEM RESPONSE AND DROP TEST
Additional auxiliary channels 3 and 4 are available for granular or liquid rate
control. Channel Setup screens require the same configuration parameters,
calibration, and drop test requirements as channels 1 and 2. Refer to the
Granular and Liquid Configuration sections for additional information.
SPINNER SYSTEM RESPONSE CALIBRATION
When “F4 Aux S” is assigned as Spinner, performing a Spinner System
Response determines PWM Offset and PWM Saturation values when using
a proportional valve with no feedback sensor to drive the spinner channel.
Spinner calibration allows for open loop or closed loop operation of the
spinner to coordinate spread width knob position with a specific spread
width for lane mile material application.
To perform a Spinner System Response Test:
1. At the System Calibration screen (F6), select Spinner System
Response and follow the onscreen instructions.
2. At the Spinner System Response screen, press “R” to begin test.
3. Spinner will be set to off when the calibration starts. Slowly rotate the
knob clockwise until the minimum spinner speed is achieved.
4. Press R to run.
5. When the desired offset is achieved, press C to capture the offset.
6. Rotate the spinner knob clockwise until the maximum spinner speed is
achieved.
7. Press C to capture the saturation.
8. Spinner calibration is complete. Press D to exit.
9. libration drop test.
NOTE: Calibration Data Sheets are
available in the back of this
manual to record constants.
A warning message indicates material will dispense when
procedure is started. Ensure all personnel are clear before
starting the next step.
Figure 97
Spinner System Response Screens
(LIQUID/GRANULAR 5‐8) (LIQUID/GRANULAR 5‐8) 1.
2.
3.
4.
112 / CALIBRATIONS
AUX S SYSTEM RESPONSE (LIQUID/GRANULAR 9‐12) AUX S DROP TEST (LIQUID/GRANULAR 9‐12) SPINNER SYSTEM RESPONSE SPINNER SPREAD WIDTH Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
Figure 98
Spinner System Response Screens
Flex4 ProTM Control System
6010541 Rev A
CALIBRATIONS / 113
OPERATOR’S MANUAL
SPINNER SPREAD WIDTH
A spinner spread width calibration adjusts to the spinner configuration
settings defined at the Spinner Calibration screen and correlates these
settings to the increase and decrease adjustment of the spread width knob
automatically adjusting the amount of material applied. A spread width bar
graph displays on the Operate screen to indicate spread width percentage.
IMPORTANT: A spinner spread width calibration can only be
performed when spinner units are selected as feet on
the Spinner Configuration (F4) screen.
To perform a Spinner System Response Calibration:
1. Load vehicle with material.
2. At the F6 Calibration menu, select Spinner Spread Width and follow
onscreen instructions.
3. Position a suitable container to catch all granular material dispensed
from the conveyor/auger. The larger the sample weighed, the better
the accuracy. The container must be large enough to obtain a good
representative sample.
4. Press C to proceed to further calibration instruction.
5. Press S to start calibration.
Figure 99
Spinner Spread Width
6. When a sufficient amount of material has dispensed, press “C” to
pause the calibration.
7. Measure the material dispensed and enter the spread width amount in
inches into the Spread Width popup window. This process is required
an additional 4 times to calculate an average that appears on the
screen each time another calibration is ran.
114 / CALIBRATIONS
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
8. After the final calibration, a calibration complete screen appears.
Press “D” to return to the main Calibration screen.
Figure 100
Spinner Spread Width
Enter measured spread width into popup window Flex4 ProTM Control System
6010541 Rev A
CALIBRATIONS / 115
OPERATOR’S MANUAL
GROUND SPEED CONFIGURATION (F8)
Ground speed configuration sets the parameters for ground speed type and
performs a calibration.
Figure 101
Ground Speed Configuration
GROUND SPEED SOURCE
CAN
Used when ground speed is provided by a radar/digital (3-wire) type sensor
connected to the cab harness or if radar/forward ground speed is
communicated on the CAN bus.
DIGITAL
Used when ground speed is provided by a radar/digital (3-wire) type sensor
connected to the actuator harness.
RELUCTANCE
Used when ground speed is provided by a reluctance (2-wire) type sensor
connected to the actuator harness through an adapter harness.
MAXIMUM CONTROL SPEED
Indicates the allowed maximum speed in AUTO mode before a Maximum
Speed Exceeded warning occurs. The value entered is based on the
highest speed for acceptable system performance. If a zero is entered, the
function is disabled.
MANUAL SPEED ON
Manual Speed On overrides the current system when the ground speed
sensor is not operating properly. An internally-generated ground speed
signal allows for continued operation and can also be used for testing,
troubleshooting, or calibrating the vehicle while stationary.
MANUAL SPEED ACCESS
Allows the operator to activate the manual speed mode when necessary.
Manual speed can be enabled and disabled at the Material Selection
screen.
116 / CALIBRATIONS
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OPERATOR’S MANUAL
MAXIMUM MANUAL SPEED
Sets the maximum manual ground speed allowed to spread the target APR.
MANUAL SPEED
Represents the ground speed in miles per hour with an artificial,
internally-generated signal. Vehicle speed should run close to the
maximum manual speed to ensure materials are spread to the target APR.
CONTROL STARTUP SPEED
The speed the system begins to operate when ground speed sensor pulses
start. Until this threshold is crossed, the startup ground speed signal is
used.
CONTROL SHUTOFF SPEED
Minimum ground speed allowed before the system stops operation. It is
recommended that shutoff speed be set at 0.0 unless speed appears from a
mechanical sensor.
GROUND SPEED CONSTANT
Determines the number of pulses received from the ground speed sensor
per mile of travel. If unknown, the value automatically calculates during a
ground speed calibration.
Flex4 ProTM Control System
6010541 Rev A
CALIBRATIONS / 117
OPERATOR’S MANUAL
GROUND SPEED CALIBRATION (F8)
Ground speed calibration establishes a ground speed constant(s) for the
vehicle. The constant is determined by counting the number of ground
speed sensor pulses generated in a distance of one mile.
Figure 102
Ground Speed Calibration Screens
118 / CALIBRATIONS
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
To establish a Ground Speed Constant:
1. Accurately measure one mile marking the start and finish points.
Markers should be visible from the cab while driving past. Alternatively,
two highway mileage markers can be used.
2. At the Ground Speed Calibration screen (F8), press C to begin
calibration.
3. Drive to the start of the course at a minimum speed of 5 mph (8Km/hr).
4. When even with the start marker, press S on the keyboard. The
calibration begins as the vehicle is moving.
5. Drive at normal operating speed.
NOTE: For better accuracy, it is
recommended to slow down at
the second marker so reaction
time is better when pressing “S”
to stop.
Flex4 ProTM Control System
6010541 Rev A
6. At the finish marker, press C to complete the calibration.
7. Press S to save the value, press R to restart the calibration or press
Esc to abort the calibration.
8. To ensure accuracy, repeat the calibration procedure three times and
average the results. Enter the average value.
9. Record the ground speed constant on the Calibration Data Records
sheets at the rear of this manual.
CALIBRATIONS / 119
OPERATOR’S MANUAL
120 / CALIBRATIONS
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
IMPORT/EXPORT DATA FILES
Two separate functions can be performed with the Import/Export button.
•
•
Import/export of system configuration settings to a USB memory
device to import to other tablets
Export of logged data files for reporting purposes
PASSCODE ENABLED
If a driver passcode is enabled at the Configuration Setup screen, this
passcode is required before importing or exporting files can occur. The code
can be entered on the Passcode screen or by using an attached keyboard.
The Passcode screen appears after pressing the Import/Export button.
Enter the passcode and press the Enter button to proceed.
Figure 103
Passcode Screen
1 7 2 DATA
ENTER CONFIGURATION PASSCODE 8 3 IMPORT
DONE
9 YOU MUST REBOOT THE TERMINAL TO SAVE ALL IMPORTED DATA ENTER REBOOT TERMINAL 4 0 5 6 BACK
BACK
NOTE: USB memory device must be
inserted into the USB port
before the Import/Export
button appears.
Flex4 ProTM Control System
6010541 Rev A
EXPORT CONFIGURATION FILES
To export Configuration Files:
1. Insert USB memory device into USB port.
2. At the Operate screen, an Import/Export button appears after the
USB memory device is inserted.
3. Press the Import/Export button.
4. At the Import Export screen, select Config USB Export button. The
Export to USB confirmation screen displays the file name that contains
the configuration files.
5. Press the Export Now button.
6. A Data Export Done screen indicates file transfer is complete.
IMPORT/EXPORT DATA FILES / 121
OPERATOR’S MANUAL
Figure 104
Exporting Configuration Files
IMPORT/EXPORT
CONFIG
USB
IMPORT
CONFIG
USB
EXPORT
DATA
USB
EXPORT
CONFIGURATION
LOGGED DATA
BACK
EXPORT TO USB
CONFIGURATION
FILE NAME:
Flex4_Truck ID_2016-07-29
.
EXPORT
NOW
BACK
DATA
EXPORT
DONE
BACK
EXPORT LOG DATA FILES
Log data files are exported following the same procedure as exporting
configuration files. Log data files can be imported to a reporting software
tool to create truck fleet reports.
To export Log Data Files:
1. Insert USB memory device into USB port below the Operator Switch
Module.
122 / IMPORT/EXPORT DATA FILES
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OPERATOR’S MANUAL
2. Press the Import/Export button.
3. At the Import Export screen, select Data USB Export button. The
Export to USB confirmation screen displays the file name that contains
the configuration files.
4. Select the type of export to perform.
– Export Now- Exports files
– Export and Clear Totals- Exports files and clears all current totals
in lieu of individually clearing each material total at the Totals
screen.
5. A Data Export Done screen indicates file transfer is complete.
Figure 105
Export Log Data Files
IMPORT/EXPORT
CONFIG
USB
IMPORT
CONFIG
USB
EXPORT
DATA
USB
EXPORT
CONFIGURATION
LOGGED DATA
BACK
EXPORT TO USB
LOGGED DATA
FILE NAME:
Flex4_Truck ID_2016-07-29.
EXPORT &
CLEAR
TOTALS
Logged Data Files Export in Progress EXPORT
NOW
BACK
DATA
EXPORT
DONE
PLEASE REMOVE STORAGE DEVICE AND CHECK THAT DATA WAS EXPORTED CORRECTLY WOULD YOU LIKE TO CLEAR CURRENT TOTALS? PRESS BACK TO EXIT AND PRESERVE TOTALS Flex4 ProTM Control System
6010541 Rev A
BACK
IMPORT/EXPORT DATA FILES / 123
OPERATOR’S MANUAL
EXPORT FILE STRUCTURE
The export file structure when exporting configuration and log data files to a
USB memory device is formatted as follows:
•
•
A folder is created that Flex4 data is stored (Flex4_DataFolder)
Each time an export occurs the file name is saved with the Flex4 name
identifier, the Truck ID, date of the download, and time of the download
FILE STRUCTURE: Flex4_DataFolder/Flex4_TruckID_Date_Time
EXAMPLE:
124 / IMPORT/EXPORT DATA FILES
Flex4_DataFolder/Flex4_42067_2011-09-14_15-00-39
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
IMPORT CONFIGURATION FILES
To import Configuration Files:
1. Insert USB memory device into USB port.
2. At the Operate screen an Import/Export button appears after the USB
memory device is inserted.
3. At the Import/Export screen, select Config USB Import button. This
button only appears if files exist on the USB memory device.
4. Select the desired file to import and press the Import File button.
5. Select the desired file types to import and press the Import Now
button.
– A Data Import screen indicates file(s) are loaded.
Figure 106
Importing Configuration Files
IMPORT/EXPORT
CONFIG
USB
IMPORT
CONFIG
USB
EXPORT
DATA
USB
EXPORT
CONFIGURATION
LOGGED DATA
BACK
IMPORT FROM USB
SELECT FILE FROM BELOW LIST
Dj_Flex4_Settings_42067.xml IMPORT
FILE
BACK
IMPORT SETTINGS
SELECT DATA TO BE IMPORTED
CONFIGURATIONS
ROUTE NAMES
DRIVER NAMES
PASSCODES
IMPORT
now
BACK
USE TERMINAL KEYS TO SELECT DATA DATA
IMPORT
DONE
BACK
Flex4 ProTM Control System
6010541 Rev A
IMPORT/EXPORT DATA FILES / 125
OPERATOR’S MANUAL
6. Press the Reboot button to turn the system off and on again to accept
imported data.
Figure 107
Rebooting the Tablet
DATA
IMPORT
DONE
YOU MUST REBOOT THE TERMINAL TO SAVE ALL IMPORTED DATA REBOOT SYSTEM BACK
BACK
126 / IMPORT/EXPORT DATA FILES
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6010541 Rev A
OPERATOR’S MANUAL
CAPTURE SCREEN SHOT
A screen shot of the active screen is possible by pressing and holding
anywhere on the screen for approximately 3 seconds.
A gray box appears underneath the finger press when the image is
captured and transferred to a USB memory device.
The USB memory device must be inserted before a screen capture is
possible.
To Capture Screen Shot:
1. Insert USB memory device.
2. At the desired screen, press and hold until a gray box appears
underneath finger press.
3. Remove USB memory device.
Figure 108
Screen Shot
Flex4 ProTM Control System
6010541 Rev A
CAPTURE SCREEN SHOT / 127
OPERATOR’S MANUAL
128 / CAPTURE SCREEN SHOT
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
DIAGNOSTICS
Diagnostic screens (F7) can be used to check system performance by
displaying sensor input readings that connect to the PCECU, control
module, and output module that could indicate potential issues.
Three Diagnostic screens are available and selected based on where the
sensor is connected:
•
•
•
NOTE: After plugging in the keyboard,
the Flex4 ProTM tablet screen
must be touched first before the
keyboard becomes active and
usable.
PCECU (joystick inputs)
Control module (control channels, spinner, auxiliary sensors)
Output module (added accessories)
PERFORM A DIAGNOSTICS CHECK (F7)
To perform a diagnostics check, vehicle ground speed must be zero and
manual ground speed must be enabled at the appropriate ground speed
setting. Actual readings will display on the Diagnostics screen at the defined
rate and the manual ground speed entered when the switch module Auto
On button is enabled.
Enable Manual Ground Speed:
1. Enable manual ground speed with the vehicle stopped and the switch
module Auto On/Off button in Off mode.
2. At the Operate screen, press the Material Select button to display the
Material Selection screen.
3. Press the Manual Speed button to select Enable Manual Speed.
4. Press the Select button to enter the appropriate ground speed to
perform test.
5. Press the Back button to return to the Operate screen. Verify that the
manual speed is active on the screen.
6. Connect the keyboard to access the Diagnostics screen and press the
F7 button on the keyboard to display the Diagnostics screen.
Flex4 ProTM Control System
6010541 Rev A
DIAGNOSTICS / 129
OPERATOR’S MANUAL
Figure 109
Enable Manual Ground Speed
O.O Increase/ decrease manual speed To Perform a Diagnostics Check:
1. Press the appropriate number on the keyboard to select the PCECU,
control module, or output module screens.
2. At the selected Diagnostics screen, press the switch module Auto On/
Off button to On to display system readings.
Figure 110
Main Diagnostic Screen
PCECU 130 / DIAGNOSTICS
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
DISPLAY PCECU
The PCECU screen indicates the current state of the joystick inputs as
either ON or OFF. Pressing the appropriate joystick function while on this
screen indicates if the joystick is functioning properly.
– An incorrect state on the screen that doesn’t correspond with the
actual joystick function could indicate the joystick is not wired
correctly or a defective joystick.
Figure 111
PCECU Diagnostics Screen
DISPLAY PCECU CONTROL MODULE
The Control Module Diagnostics screen provides sensor readings for
control channels, auxiliary channel, spinner, and accessory sensors. Any
misreadings could indicate a control module problem, a faulty sensor, or
bad sensor connection.
1. At the Main Diagnostics screen, press 2 on the keyboard to display the
Control Module Diagnostics screen.
2. Select the appropriate material (Granular, Liquid, Aux, Aux S), spinner,
or accessory sensor to perform the relevant diagnostic check.
Figure 112
Control Module Diagnostics Screen
Flex4 ProTM Control System
6010541 Rev A
DIAGNOSTICS / 131
OPERATOR’S MANUAL
MATERIAL
Target Rate
Target Rate displays the defined application rate set at the configuration
screen and the rate the Diagnostics screen will perform the test.
– Target rate can be adjusted at the Operate screen by pressing the
Increase/Decrease Rate buttons on the switch module to achieve
the desired target rate.
Actual Rate
Actual rate is the rate that is being applied during the test. The Actual Rate
should match or run closely to the Target Rate.
– A wrong actual rate could indicate that a system response should
be performed or a faulty feedback sensor.
Set Point
Set Point, displayed in hertz, is the pulses per second required for the
feedback sensor to achieve the target rate at the manual ground speed set.
– No set point could indicate a configuration issue or faulty master
module.
Filtered Feedback
Filtered Feedback is the actual pulses per second of the feedback sensor
and indicates the PWM signal being sent to the hydraulic control valve.
– No filtered feedback could indicate a faulty feedback sensor.
Pulse Count
Pulse Count reading indicates pulses sent from the feedback sensor to the
rate control module.
Output PWM
Output PWM indicates the current PWM signal and continues to increase
until the desired target rate is reached and then should remain steady when
achieved.
RPM
RPM indicates the revolutions per minute of the conveyor/auger.
Ground Speed Frequency
Ground Speed Frequency identifies the pulses per second coming into the
control module and could indicate a potential problem with the module, not
reading a signal from the sensor, or a speed sensor failure.
Voltage readings from the truck battery are displayed for the following:
–
–
–
–
132 / DIAGNOSTICS
Solenoid Power
Solenoid Ground
ECU Power
ECU Ground
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
SPINNER
The Spinner Diagnostics screen provides readings related to the rotary
spinner knob on the operator switch module and corresponding PWM signal
being sent to the coil controlling oil flow to the spinner motor.
Any misreadings could indicate a faulty switch module or rate control
module.
Figure 113
Spinner Diagnostics
AUX 2 Target Rate
Only applicable if spinner is set for RPM control or GSRS mode.
Output PWM
Output PWM indicates the current PWM signal and continues to increase
until the desired target rate is reached and then should remain steady when
achieved.
Ground Speed Frequency
Ground Speed Frequency identifies the pulses per second coming into the
control module and could indicate a potential problem with the module, not
reading a signal from the sensor, or a speed sensor failure.
Voltage Readings
Voltage readings from the truck battery are displayed for the following:
–
–
–
–
Flex4 ProTM Control System
6010541 Rev A
Solenoid Power (voltage from battery to solenoid relays)
Solenoid Ground (voltage from battery to solenoid relays)
ECU Power (voltage present at rate controller module)
ECU Ground (voltage present at rate controller module)
DIAGNOSTICS / 133
OPERATOR’S MANUAL
Accessory Sensors
Voltage readings of accessory sensors relate to voltage feedback from
specific sensors in their current position. When sensor position changes,
the voltage reading changes.
– A zero (0) voltage reading indicates a faulty sensor or bad
connection.
Ground Speed Frequency
Ground Speed Frequency identifies the pulses per second coming into the
control module and could indicate a potential problem with the module, not
reading a signal from the sensor, or a speed sensor failure.
Voltage Readings
Voltage readings from the truck battery are displayed for the following:
–
–
–
–
Solenoid Power (voltage from battery to solenoid relays)
Solenoid Ground (voltage from battery to solenoid relays)
ECU Power (voltage present at rate controller module)
ECU Ground (voltage present at rate controller module)
Figure 114
Accessory Sensor Diagnostics
134 / DIAGNOSTICS
AUX S AUX S Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
OUTPUT MODULE
Output Module Diagnostics screen indicates the current state of attached
accessories such as boom section shutoff valves, V-Box gate, front/rear
conveyor valves, left/right discharge cross conveyors valves, and the
accessory 12 volt switched output.
Press the appropriate Accessory button to verify correct position. An
incorrect state on the screen that doesn’t correspond with the
physical state of the attached accessory could indicate a
communication issue with the Output Module.
Figure 115
Output Module Diagnostics Screen
Accessory Buttons Flex4 ProTM Control System
6010541 Rev A
DIAGNOSTICS / 135
OPERATOR’S MANUAL
136 / DIAGNOSTICS
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
TROUBLESHOOTING
Error messages display when an abnormal event occurs. For any failure
that persists, contact DICKEY-john Technical Support at 1-800-637-3302.
Flex4 ProTM Control System
6010541 Rev A
TROUBLESHOOTING / 137
OPERATOR’S MANUAL
ERROR
CODE
ERROR
PROBABLE CAUSE
CORRECTIVE ACTION
10
Rate Controller Stack Alarm
Internal system software error.
Cycle system power off and on.
11
Rate Controller System
Stack Alarm
Internal system software error.
Cycle system power off and on.
50
Rate Controller Offline Alarm
Communication to the rate controller has been lost.
1. Verify rate control module has a good
connection.
2. Inspect CAN harness for damage.
3. Inspect ECU harness and fuse for damage.
4. Inspect ECU for damage.
51
Rate Controller Intermittent
Alarm
Communication to the rate controller was lost but
has been re-established.
Check for intermittent connections.
1. Verify rate control module has a good
connection.
2. Inspect CAN harness for damage.
3. Inspect ECU harness and fuse for damage.
4. Inspect ECU for damage.
52
Remote Operator Controller
Offline Alarm
Communication to the switch module has been lost.
1. Verify switch module is connected properly.
2. Inspect CAN harness for damage.
3. Inspect ECU harness and fuse for damage.
4. Inspect ECU for damage
53
Output Module Offline Alarm
Output member module is no longer online.
1. Verify output module is connected properly.
2. Inspect CAN harness for damage.
3. Inspect ECU harness and fuse for damage.
4. Inspect ECU for damage
54
Output Module Intermittent
Alarm
Communication to the output module was lost but
has been re-established.
Verify output module is connected properly.
2. Inspect CAN harness for damage.
3. Inspect ECU harness and fuse for damage.
4. Inspect ECU for damage
55
PCECU Offline Alarm
Member module is no longer online.
1. Verify module is connected properly.
2. Inspect CAN harness for damage.
3. Inspect ECU harness and fuse for damage.
4. Inspect ECU for damage
56
PCECU Intermittent Alarm
Communication to the member module was lost but
has been re-established.
Verify module is connected properly.
2. Inspect CAN harness for damage.
3. Inspect ECU harness and fuse for damage.
4. Inspect ECU for damage
200
Auto has been turned off
alarm
Master switch was left on (auto) and is now in a
state that does not allow the system to run.
Turn Auto off before entering setup mode with
keyboard. Check connections to feedback
sensors.
222
Valve Calibration Abort Alarm
Control channel valve calibration has been aborted
due to an error.
Try calibration again.
206
“Channel” Auto Open (In
Manual Control)
A manual override state occurs when an application
rate sensor or flow meter fails. Manual override
allows material to be spread at the same
programmed rate without interruption. When a
failure occurs, the rate decreases to “0” and
“Manual” replaces the material name. Rate returns
from “0” back to target rate while manual override is
enabled. Material may be over or under applied in
this mode.
Check feedback sensors, i.e., application rate
sensors and flow meters.
208
“Channel” Application Rate
error (granular)
A fully open valve is indicated but the target APR
cannot be achieved.
1. Reduce the truck ground speed to allow the
system to catch up and the error to clear.
2. Shift to a lower gear to increase engine RPM
and hydraulic pump rotation.
3. Check hydraulic disconnects and filter.
4. Ensure correct spreader constant is
programmed into console. Check original setting
or run a granular calibration.
5. Incorrect PWM SAT setting (See Granular
Configuration screen). Compare against original
setting or run system response on the granular
channel setting.
6. Check for insufficient hydraulic oil flow at
normal engine RPM.
7. Check spreader valve, electrical connections to
the valve coil, resistance of the coils (See
manufacturers specifications), and verify voltage
from control console.
138 / TROUBLESHOOTING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
ERROR
CODE
208
ERROR
“Channel” Application Rate
Error (liquid)
PROBABLE CAUSE
A fully open valve is indicated but the target APR
cannot be achieved.
CORRECTIVE ACTION
1. Check to see if the liquid tanks are low, shutoff
valves are partially closed, bypass valves are
open too far, or an obstruction is in the liquid tank
outlet.
2. Check filters between the liquid tank and
suction side of the liquid pump for blockage.
3. Check for plugged nozzles or nozzles that are
too small to supply sufficient gallons per minute.
4. If using a electric liquid pump, check that the
nozzle pressure (spray bar pressure) does not
exceed 40 psi. Some electric pumps have an
internal pressure switch to shut pump off high
back pressure conditions.
5. Ensure a correct K-FACTOR is programmed.
Compare it against the number stamped on the
flowmeter body or recorded on the Calibration
Data Record Sheet. If original settings are not
available, run a liquid calibration.
6. Observe the PWM SAT under the Liquid
Configuration screen. Compare against original
setting. If not available, run a system response on
the liquid channel.
250
Prewet Channel Disabled
Prewet is not linked to a granular channel.
The system cannot run as configured.
1. Setup a granular channel to use as a reference
for the prewet application.
2. Or change the prewet channel type.
300
Invalid Gate Height Sensor
Configuration
The calibration points of the gate height are
incorrect. Most likely, the values do not follow an
increasing or decreasing only pattern.
1. Check calibration numbers and re-run
calibration.
2. or accept default values and continue
calibration.
301
Invalid Gate Height Open
Calibration
The open calibration point is near zero. A zero full
open position is not valid.
1. Check calibration numbers and re-run
calibration.
2. or accept default values and continue
calibration.
302
Invalid Temperature
Calibration
Temperature calibration did not complete.
1. Verify temperature sensor adapter is
connected and the temperature sensor is
disconnected. With adapter connected and
sensor unplugged, the signal should toggle
between 0.7V and 2.7V.
400
GPS Signal Low
Poor GPS signal
1. Verify GPS is enabled at the F10 screen.
2. GPS signal may be blocked. Move to a clear
area.
3. Check that receiver connection is secure.
401
Data Memory Near Full
Memory for storing operation data is running low.
1. Export data to a USB memory device.
402
Data Log Memory Full
Memory for operation is full and no additional data
can be saved.
1. Export data to a USB memory device.
403
Invalid Task Data
A task controller device error may occur on systems
with previous software versions when loading new
software.
1. Acknowledge alarm and follow onscreen
instructions
2. Insert a USB memory device.
3. Export files.
500
Gate High
Gate is above the open or highest calibrated point.
1. Check sensor and calibrations.
501
Gate Low
Gate is below the closed or lowest calibrated point.
1. Check sensor and calibrations.
502
Bed Height Too High
Bed is above the alarm value.
1. Lower bed or check sensor.
503
Down Pressure Too High
Down pressure has exceeded the alarm threshold.
1. Reduce down pressure or check sensor.
504
TankPressureLow
Tank level has dropped below alarm level.
1. Fill Tank.
2. Adjust alarm level setting.
3. Check sensor.
505
Air Temp Below Alarm Value
1
Temperature has dropped below alarm threshold.
1. Adjust alarm setting.
2. Check sensor.
506
Air Temp Below Alarm Value
2
Temperature has dropped below alarm threshold.
1. Adjust alarm setting.
2. Check sensor.
507
Air Temp Below Alarm Value
3
Temperature has dropped below alarm threshold.
1. Adjust alarm setting.
2. Check sensor.
Flex4 ProTM Control System
6010541 Rev A
TROUBLESHOOTING / 139
OPERATOR’S MANUAL
ERROR
CODE
ERROR
PROBABLE CAUSE
CORRECTIVE ACTION
508
Road Temp Below Alarm
Value 1
Temperature has dropped below alarm threshold.
1. Adjust alarm setting.
2. Check sensor.
509
Road Temp Below Alarm
Value 2
Temperature has dropped below alarm threshold.
1. Adjust alarm setting.
2. Check sensor.
510
Road Temp Below Alarm
Value 3
Temperature has dropped below alarm threshold.
1. Adjust alarm setting.
2. Check sensor.
511
Digital Accessory 1 Active
512
Digital Accessory 1 High
Sensor has reached the defined high alarm limit
value.
1. Adjust alarm setting.
2. Check sensor.
513
Digital Accessory 1 Low
Sensor has reached the defined low alarm limit
value.
1. Adjust alarm setting.
2. Check sensor.
514
Digital Accessory 1
Shutdown
Digital accessory sensor has reached the defined
alarm limit and the control has been shutdown to
protect the system.
1. Adjust alarm setting.
2. Check sensor.
515
Digital Accessory High
Shutdown
Sensor has reached the defined high alarm
shutdown limit and the control has been shutdown
to protect the system.
1. Adjust alarm setting.
2. Check sensor.
516
Digital Accessory Low
Shutdown
Sensor has reached the defined low alarm
shutdown limit and the control has been shutdown
to protect the system.
1. Adjust alarm setting.
2. Check sensor.
517
Digital Accessory 2 Active
518
Digital Accessory 2 High
Sensor has reached the defined high alarm limit
value.
1. Adjust alarm setting.
2. Check sensor.
519
Digital Accessory 2 Low
Sensor has reached the defined low alarm limit
value.
1. Adjust alarm setting.
2. Check sensor.
520
Digital Accessory 2
Shutdown
Digital accessory sensor has reached the defined
alarm limit and the control has been shutdown to
protect the system.
1. Adjust alarm setting.
2. Check sensor.
521
Digital Accessory High
Shutdown
Sensor has reached the defined high alarm
shutdown limit and the control has been shutdown
to protect the system.
1. Adjust alarm setting.
2. Check sensor.
522
Digital Accessory Low
Shutdown
Sensor has reached the defined low alarm
shutdown limit and the control has been shutdown
to protect the system.
1. Adjust alarm setting.
2. Check sensor.
523
Hopper Low
Hopper level is low.
1. Fill hopper.
2. Check sensor.
604
ECU Low Voltage
1. Damaged CAN or module harness.
2. Defective module
1. Inspect CAN/module harness of the module for
damage.
2. Inspect module for damage and replace, if
necessary.
605
ECU High Voltage
1. Damaged CAN or module harness.
2. Defective module
1. Inspect CAN/module harness of the module for
damage.
2. Inspect module for damage and replace, if
necessary.
606
Solenoid Low Voltage
1. Damaged CAN or module harness.
2. Blow module harness fuse.
3. Defective module.
1. Inspect CAN/module harness of the module for
damage.
2. Inspect module harness fuse and replace, if
necessary.
3. Inspect module for damage and replace if
necessary.
607
Solenoid Voltage with
Control Shutdown
Solenoid voltage is too high and the control system
has shutdown.
1. Voltage issue must be corrected before control
can resume.
140 / TROUBLESHOOTING
1. Adjust alarm setting.
2. Check sensor.
1. Adjust alarm setting.
2. Check sensor.
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
ERROR
CODE
ERROR
PROBABLE CAUSE
CORRECTIVE ACTION
608/609
Ground Low/High Voltage
Ground offset measurement out of range:
1. ECU ground or Solenoid ground have a poor
connection.
2. Damaged/shorted actuator harness.
3. Defective PWM valve driver or Servo valve driver.
4. Defective module.
Check GROUND voltage on Diagnostic screen
for Control Module, then:
1. Check battery ground connections and wiring.
2. Inspect actuator harness for damage around
the PWM and Servo valve connections. Repair
or replace harness.
3. Inspect PWM or Servo valve drivers for
damage and replace if necessary.
4. Inspect module for damage and replace if
necessary.
701
Service Keyboard Mode
A mode that allows keyboard use when ground
speed is above 0 and the master switch is OFF.
1. Service Keyboard Mode is enabled at the F10
System screen. Warning continues to displays
until the function is disabled.
Flex4 ProTM Control System
6010541 Rev A
TROUBLESHOOTING / 141
OPERATOR’S MANUAL
142 / TROUBLESHOOTING
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
APPENDIX A
CHANNEL
DESIGNATION
ASSIGNED TYPES
OPTIONS
GRANULAR
Granular
PWM Only
3
LIQUID
Liquid
PWM/Servo, Liquid - Pre-Wet,
Anti-Ice, or Vol/Area
1
AUX-S
Liquid, Granular, Spinner
(PWM)
PWM Only, Liquid - Pre-Wet,
Anti-Ice, or Vol/Area
4
AUX
Liquid, Granular (PWM/Servo)
PWM/Servo, Liquid - Pre-Wet,
Anti-Ice, or Vol/Area
2
Channel I/O #
Channel Linking Conditions and Recommendations
1. If GRANULAR is set to “Enable”, and LIQUID is configured as
PREWET, then LIQUID rate is linked to GRANULAR.
2. If AUX-S is configured as GRANULAR and AUX is configured as
PREWET, then AUX rate is linked to AUX-S.
3. If GRANULAR is set to “Enable”, and AUX is configured as PREWET,
and AUX-S is NOT Granular, then AUX rate is linked to GRANULAR.
4. If GRANULAR is set to “Enable”, and AUX is configured as PREWET,
and AUX-S is configured as PREWET, then AUX and AUX-S rates are
linked to GRANULAR.
5. If two separate GRANULAR-PREWET pairs are needed, configure the
system to comply with rules #1 and #2.
Examples
Single Granular, Spinner
GRANULAR
ENABLED
PWM
LIQUID
NOT USED
NOT USED
AUX-S
SPINNER
PWM
AUX
NOT USED
NOT USED
Single Granular, Pre-Wet, Spinner
Flex4 ProTM Control System
6010541 Rev A
GRANULAR
ENABLED
PWM
LIQUID
PRE-WET
PWM/SERVO
AUX-S
SPINNER
PWM
AUX
NOT USED
NOT USED
APPENDIX A / 143
OPERATOR’S MANUAL
Single Granular, Anti-Ice, Spinner
GRANULAR
ENABLED
PWM
LIQUID
LIQUID ANTI-ICE
PWM/SERVO
AUX-S
SPINNER
PWM
AUX
NOT USED
NOT USED
Tow Plow (2 Granular, 2 Pre-Wet)
144 / APPENDIX A
GRANULAR
ENABLED
PWM
LIQUID
LIQUID PRE-WET
PWM/SERVO
AUX-S
GRANULAR
PWM
AUX
LIQUID PRE-WET
PWM/SERVO
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
APPENDIX B CONVERTING CONSTANTS
FINE TUNING APPLICATION
Adjusting Granular Constants
If small (less than 10%) but consistent granular APR errors (either high or
low) are observed over a period of time, fine tuning of the system can be
performed by adjusting the value of the spreader constant by the same
percentage as follows:
New SPR CON = Old SPR CON x
Target APR
Actual APR
EXAMPLE: If SPR CON is 100 and Target APR is 300 LBS/MILE but Actual
APR is known to be 315 LBS/MILE, adjust SPR CON using the above
formula:
New SPR CON = 100 x
300 = 95.2
315 NOTE: Keyboard enter the new SPR CON on the appropriate (Granular)
configuration screen.
Adjusting Liquid Constants
In a manner similar to that for granular (shown above,), liquid APR errors
can be corrected by fine tuning the flowmeter constant (K-FACTOR) as
follows:
New K-FACTOR = Old K-FACTOR x Target APR
Actual APR
EXAMPLE: If K-FACTOR is 1,000 and Target APR is 10 GAL/MILE, but
Actual APR is known to be 9.5 GAL/MILE, adjust K-FACTOR using the
above formula:
New K-FACTOR = 1000 x
Flex4 ProTM Control System
6010541 Rev A
10
9.5
= 1053
APPENDIX B CONVERTING CONSTANTS / 145
OPERATOR’S MANUAL
CALCULATING SPREADER CONSTANTS
The spreader constant can be calculated if the following is known:
A = Number of pulses per revolution of the sensor shaft.
B = Turns of the sensor shaft for each turn of the final shaft.
C = Pounds of material discharged per revolution of the final shaft.
SPR CON =
A xB
Pulses Per Pound
C
EXAMPLE:
A = 360 pulses per revolution (for Dj sensor p/n 46436-017X).
B = 25 turns of the sensor shaft for each turn of the final shaft.
C = 50 pounds of material discharged per revolution of final shaft.
SPR CON =
360 x 25 = 180 P/LB
50
NOTES:
1. V-Box spreaders have a different SPR CON for each gate setting.
2. The number of pulses per revolution for several Dj shaft sensors are:
360 for p/n 46436-017X (standard DICKEY-john shaft sensor).
60 for p/n 10844-000X
180 for p/n 464361500S1
146 / APPENDIX B CONVERTING CONSTANTS
Flex4 ProTM Control System
6010541 Rev A
OPERATOR’S MANUAL
APPENDIX C
Flex4 ProTM Control System
6010541 Rev A
APPENDIX C / 147
Operator’s Manual
™
FLEX4
PRO
PUBLIC WORKS CONTROL SYSTEM
®
DICKEY-john, and the DICKEY-john Logo
are registered trademarks, and Flex4 is a
trademark of DICKEY-john.
SINCE 1966
P/N 6010541 Rev A
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