operator`s manual - DICKEY-john
OPERATOR’S MANUAL
Safety Notices ..................................................................................................... 1
Introduction ......................................................................................................... 3
Features ............................................................................................................................ 3
Requirements .................................................................................................................... 3
Component Overview ......................................................................................... 5
Flex4 Terminal .................................................................................................................. 5
Terminal Buttons .............................................................................................................................. 6
Terminal Connections ...................................................................................................................... 6
Operator Remote Switch Module....................................................................................... 7
Switch Module Functions ................................................................................................................. 7
Rate Control Module ......................................................................................................... 8
Output Module ................................................................................................................. 10
Miscellaneous Components ............................................................................................ 12
Keyboard ........................................................................................................................................
Ground Speed Sensor ...................................................................................................................
Road Temperature Adapter (Optional) ...........................................................................................
Feedback/Application Rate Sensor (Optional) ...............................................................................
Gate Height Sensors (Optional) .....................................................................................................
Hydraulic Pressure Sensors (Optional) ..........................................................................................
Flow Meters ....................................................................................................................................
Valve Control Output ......................................................................................................................
Harnesses ......................................................................................................................................
Hopper Level Sensor (Optional) .....................................................................................................
GPS Receiver (Optional) ................................................................................................................
Video Camera (Optional) ...............................................................................................................
12
12
12
13
13
13
13
13
13
13
13
13
Installation ......................................................................................................... 15
Switch Module Mount ...................................................................................................... 15
Switch Module Bracket Assembly .................................................................................................. 15
RAM Mount Bracket Installation ...................................................................................... 16
Cab Terminal Bracket Assembly .................................................................................................... 17
Remote Switch Module Bracket Kit ................................................................................. 18
System Harness Connections.......................................................................................... 19
Cab Harness ..................................................................................................................................
Rate Control Module Harness ........................................................................................................
Roadwatch Temperature Adapter and Flex4 Interface Cable ........................................................
Extension Harness .........................................................................................................................
Output Module Harness .................................................................................................................
Electric Motor Driver Harness ........................................................................................................
21
21
23
23
24
24
Operate Screen ................................................................................................. 25
(1) Control Channels ......................................................................................................................
(2) Display Function Buttons ..........................................................................................................
(3) Spread Width Bar .....................................................................................................................
(3) Rad/Air Temperature Sensors ..................................................................................................
(3) Boom Sections ..........................................................................................................................
(3) Conveyor ..................................................................................................................................
(3) Alarms .......................................................................................................................................
(4) Accessory Sensors/Alarms .......................................................................................................
(5) Ground Speed/Time/Date .........................................................................................................
25
26
26
26
26
26
26
26
26
Display Settings (Camera/Display/Alarms) ..................................................................... 27
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Operation .......................................................................................................... 29
Pre-operating Checklist ..................................................................................................
Spreading Material .........................................................................................................
Blast ................................................................................................................................
Pause .............................................................................................................................
Material Selection ...........................................................................................................
29
29
30
31
32
Turn Off an Active Channel ............................................................................................................ 33
Unload Material ..............................................................................................................
Manual Ground Speed Override .....................................................................................
Automatic Manual Control Channel Override .................................................................
Driver Login ....................................................................................................................
Route Selection ..............................................................................................................
Boom Section Control .....................................................................................................
Anti-ice Feature ..............................................................................................................
Accessory Sensors .........................................................................................................
33
35
36
37
37
38
39
39
Output Module Accessories ............................................................................................................ 39
Hydraulic Accessory Tool Operation .............................................................................. 41
Current and Season Run Totals ..................................................................................... 41
Flex4 Programming .......................................................................................... 43
Passcode Restrictions .................................................................................................... 43
Using the Keyboard ........................................................................................................ 44
Keyboard Functions ........................................................................................................ 44
Text Entries .................................................................................................................................... 45
Label Entries ................................................................................................................................... 46
Number Entries ............................................................................................................................... 47
System Programming ...................................................................................... 49
Operate Mode (F1) ......................................................................................................... 49
Granular Channel Setup (F2) ......................................................................................... 50
Granular Rate Setup ....................................................................................................... 51
Material Label .................................................................................................................................
Units ...............................................................................................................................................
Spreader Constant .........................................................................................................................
Calibration Gate Height ..................................................................................................................
Application Rate Method ................................................................................................................
Blast Rate .......................................................................................................................................
51
51
51
51
52
53
Granular Configuration (f2) ............................................................................................. 54
Drive Frequency .............................................................................................................................
PWM Offset ....................................................................................................................................
PWM Saturation .............................................................................................................................
System Response ..........................................................................................................................
Valve Boost ....................................................................................................................................
AFILT ..............................................................................................................................................
Material ...........................................................................................................................................
Sensor Constant .............................................................................................................................
Spreader Constant .........................................................................................................................
Calibration Gate Height ..................................................................................................................
II /
55
55
55
55
55
55
55
55
55
56
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System Programming continued.......................................................................49
Liquid Channel Setup (F3) .............................................................................................. 57
Liquid Rate Setup ........................................................................................................... 58
Material Label .................................................................................................................................
Units ...............................................................................................................................................
Application Rate Method ................................................................................................................
Target Rate ....................................................................................................................................
Minimum/Maximum Rate ...............................................................................................................
Inc/Dec Step ...................................................................................................................................
Blast Rate .......................................................................................................................................
59
59
59
60
60
60
60
Boom Configuration (Liquid/Anti-Ice) ............................................................................... 62
Function ......................................................................................................................................... 62
Active Level .................................................................................................................................... 62
Spinner Configuration (F4)............................................................................................... 63
Spinner Units ..................................................................................................................................
Unload ............................................................................................................................................
Drive Frequency .............................................................................................................................
No Ground Speed ..........................................................................................................................
Blast Rate .......................................................................................................................................
Pulse Feedback .............................................................................................................................
Spinner Constant ...........................................................................................................................
PWM Offset ....................................................................................................................................
PWM Saturation .............................................................................................................................
System Response ..........................................................................................................................
Valve Boost ....................................................................................................................................
AFILT .............................................................................................................................................
Ground Speed Related (GSRS) .....................................................................................................
GSRS Slope ...................................................................................................................................
Maximum GSRS ............................................................................................................................
63
63
63
63
64
64
64
64
64
64
64
64
64
64
65
Auxiliary Control Channel Configuration (F5) ................................................................. 65
Accessory Sensors (F9) .................................................................................................. 66
Gate Height Sensor ........................................................................................................................
Road Temperature Sensor .............................................................................................................
Air Temperature Sensor .................................................................................................................
Tank Level Sensor Configuration ...................................................................................................
Down Pressure ...............................................................................................................................
Bed Height .....................................................................................................................................
Digital Accessories .........................................................................................................................
Joystick Labels ...............................................................................................................................
67
68
70
71
72
73
74
77
System Setup (F10) ........................................................................................................ 78
Blast Setup ...................................................................................................................... 78
Blast Timer ..................................................................................................................................... 79
Blast Speed .................................................................................................................................... 79
Date and Time ................................................................................................................ 79
Units and Language ........................................................................................................ 80
Service ............................................................................................................................ 81
Software Version ............................................................................................................................ 81
System Reset ................................................................................................................................. 82
Troubleshooting .............................................................................................................. 83
GPS Sensor ................................................................................................................................... 84
Output Module Setup (F11) ............................................................................................ 85
Front/Rear Conveyor ...................................................................................................................... 85
Left/Right Conveyor ....................................................................................................................... 85
Gate Height Control ....................................................................................................................... 86
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OPERATOR’S MANUAL
System Programming continued ...................................................................... 87
Data Logging (F12) ......................................................................................................... 87
Alarm History .................................................................................................................................. 87
Truck ID .......................................................................................................................................... 88
Driver Setup .................................................................................................................... 89
Driver ID Configuration ...................................................................................................................
Configuration Setup ........................................................................................................................
Route Configuration ........................................................................................................................
Operational Totals ..........................................................................................................................
Lifetime Totals ................................................................................................................................
89
91
92
93
95
Calibrations ....................................................................................................... 97
Material and Spinner System Response Calibrations (F6) ............................................. 97
Granular Response Calibration ...................................................................................................... 97
Recording Calibration Data ............................................................................................ 98
Maintaining Calibration Accuracy ................................................................................... 99
System Response Adjustments ...................................................................................................... 99
System Response Constant ........................................................................................................... 99
Valve Boost .................................................................................................................................... 99
AFILT ............................................................................................................................................ 100
Granular Drop Test Calibration ..................................................................................... 100
Drop Test Preparation .................................................................................................................. 100
Performing a Granular Drop Test ................................................................................................. 100
Granular Calibration Adjustments ................................................................................................. 103
Liquid Drop Test Calibration (F6) ................................................................................. 103
Drop Test Preparation .................................................................................................................. 103
Performing a Liquid Drop Test ...................................................................................................... 103
Liquid Calibration Adjustments ..................................................................................................... 105
Auxiliary System Response and Drop Test .................................................................. 106
Spinner System Response Calibration ......................................................................... 106
Spinner Spread Width .................................................................................................................. 108
Ground Speed Configuration (F8) ................................................................................. 110
Ground Speed Source ..................................................................................................................
Maximum Control Speed ..............................................................................................................
Manual Speed On .........................................................................................................................
Manual Speed Access ..................................................................................................................
Maximum Manual Speed ..............................................................................................................
Manual Speed ..............................................................................................................................
Control Startup Speed ..................................................................................................................
Control Shutoff Speed ..................................................................................................................
Ground Speed Constant ...............................................................................................................
110
110
110
110
111
111
111
111
111
Ground Speed Calibration (F8) ..................................................................................... 112
Import/Export Data Files ................................................................................ 115
Passcode Enabled ........................................................................................................ 115
Export Configuration and Log Data Files ...................................................................... 115
Import Configuration Files ............................................................................................ 117
Diagnostics ..................................................................................................... 119
Perform a Diagnostics Check ....................................................................................... 119
Terminal ........................................................................................................................ 121
Control Module ............................................................................................................. 121
Material ......................................................................................................................................... 122
Spinner ......................................................................................................................................... 123
Output Module .............................................................................................................. 125
IV /
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Troubleshooting .............................................................................................. 127
Appendix A Converting Constants ............................................................... 131
Fine Tuning Application ................................................................................................ 131
Calculating Spreader Constants ................................................................................... 132
Warranty ............................................................................................................133
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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.
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INTRODUCTION
The DICKEY-john Flex4 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 will automatically stop when the truck stops.
The operator interface consists of a:
•
•
Console
Switch Module
Desired material application rates are entered on the Setup screens by
attaching a keyboard.
Figure 1
Flex4 Console and Remote Operator’s Switch Module
FEATURES
•
•
•
•
•
•
7 inch color display
4 channel closed-loop control of granular, liquid, auxiliary (liquid or
granular), and spinner functions
Summer mode feature for roadside spraying, burming, and operation
of hydraulic tools
Day/night mode
Optional camera to view rear of truck to monitor material dispensing
and to avoid potential accidents
Optional vehicle and fleet data management packages
REQUIREMENTS
The Flex4 system requires the following components for operation:
•
•
•
•
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Flex4 terminal
Operator’s remote switch module
Working set master module
Keyboard (programming only)
INTRODUCTION / 3
OPERATOR’S MANUAL
•
•
•
•
•
•
4 / INTRODUCTION
Application rate sensor on salt spreader and flow meter on prewet
system
Application rate ECU to drive hydraulic valve and electric pumps to
regulate material application
Valve control devices
Harnesses to connect system devices
Ground speed sensor (from speedometer)
GPS receiver (if vehicle tracking and data transfer is required)
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COMPONENT OVERVIEW
Components included with the Flex4 system:
•
•
•
•
•
•
•
Flex4 terminal
Flex4 terminal mounting bracket and hardware
Rate control module
Remote switch module
Remote switch module mounting bracket and hardware
Cab power harness
Rate control module harness
Optional components:
•
•
•
•
•
•
•
•
NOTE: Contact DICKEY-john Technical
Support to order optional
components at
1-800-637-3302.
10’ CAN extension harness
Output module and harness
Solenoid driver
Electric motor/pump driver
Camera 4.3mm lens
Flex4 camera adapter
20’ camera extension
Feedback sensors
FLEX4 TERMINAL
The Flex4 terminal is a 7” color display that provides simultaneous viewing
of:
•
•
•
•
•
•
•
Rates
Spread width
Vehicle speed
Spread direction
Road temperature
Joystick selection
Accessory input monitoring
Figure 2
Flex4 Terminal
Terminal
Buttons
1-6
Terminal
Buttons
7-12
Home button returns
to Operate screen or
adjusts Operate screen
layout
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OPERATOR’S MANUAL
TERMINAL BUTTONS
•
•
•
Twelve buttons are located on the left and right side of the terminal that
correspond with screen text to provide screen navigation and quick
adjustment to system settings
Home button returns to Operate screen from any screen
Home button adjusts Operate screen layout
TERMINAL CONNECTIONS
1. Video camera connection
2. Terminal harness connection
3. USB RS232 port for data download and keyboard connection. 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 display terminal and master
control module from USB memory device.
– Imports system configuration files to program each display terminal
and master control module with system calibration values.
4. Rotary button for scrolling through display menu items
Figure 3
Flex4 Terminal Side and Back View
4
3
1
6 / COMPONENT OVERVIEW
2
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OPERATOR’S MANUAL
OPERATOR REMOTE SWITCH MODULE
The Operator’s Remote 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 will display on the console. Pressing
the spread width knob will also select a channel to adjust.
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OPERATOR’S MANUAL
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.
Figure 5
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 6
Acceptable Orientation
PREFERRED
ACCEPTABLE
ACCEPTABLE
Do not install the module in any orientation other than shown in
(Figure 6). The connection wires must not be mounted upward as
moisture can collect inside the unit and damage the circuits.
8 / COMPONENT OVERVIEW
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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.
The Rate Control harness controls and provides connection to the following
inputs:
– 1 granular control channel
– 1 liquid control channel (prewet or anti-ice)
– 1 auxiliary control channel (liquid or granular)
– 1 spinner 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.
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OPERATOR’S MANUAL
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 6).
Figure 7
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 6). 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.
10 / COMPONENT OVERVIEW
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OPERATOR’S MANUAL
Figure 8
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
FASTENING
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.
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OPERATOR’S MANUAL
Figure 9
Securing Member with Tie Straps
TRUCK
FRAME
OR
BED
SUPPORT
6. Connect a 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: Be sure the locking tabs engage when inserting the
connectors. The connection is sealed only when the
locking tabs have fully engaged.
MISCELLANEOUS COMPONENTS
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.
ROAD TEMPERATURE ADAPTER (OPTIONAL)
Temperature sensors allow for direct readout of road temperature and
ambient air temperature.
12 / COMPONENT OVERVIEW
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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 capactiy
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.
GPS RECEIVER (OPTIONAL)
A GPS receiver for vehicle tracking.
VIDEO CAMERA (OPTIONAL)
A video camera installed on the rear of truck allows viewing of material
dispensing and aids in backing the vehicle.
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14 / COMPONENT OVERVIEW
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INSTALLATION
The Switch Module can be mounted next to the terminal with provided
hardware or to the armrest using an optional remote switch module mount
bracket.
The standard hardware kit includes the following components:
•
•
Ram Mount Kit (attaches terminal to vehicle dash)
Switch Module Mount (attaches switch module to terminal)
Optional remote switch module mounting hardware can be ordered
separate that mounts the switch module to the armrest.
SWITCH MODULE MOUNT
The switch module mounting bracket attaches the remote switch module to
the terminal and includes the following components:
•
•
•
•
Main switch module mounting bracket
Bracket shroud
3 Hex nuts
4 washers
SWITCH MODULE BRACKET ASSEMBLY
Attach Shroud and Module to Bracket:
1. Align shroud to the bracket (4) stud bolts.
2. Secure shroud to bracket with (4) washers.
3. 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.
4. Secure switch module to the bracket using (3) hex nuts.
Figure 10
Switch Module/Terminal Bracket
Switch Module
Stud bolts (3)
Connector
opening
3
2
4
Switch Module
Bracket
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Bracket 1
Stud Bolts (4)
Shroud
Hex Nut (3)
Washer (4)
INSTALLATION / 15
OPERATOR’S MANUAL
Attach Terminal to Switch Module Bracket:
1. Loosen wing bolt of the RAM mount bracket and remove ball mount
attachment.
2. Align the (4) holes on the switch module bracket to the terminal.
3. Align RAM ball mount with switch module bracket holes.
4. Secure terminal to bracket using (4) lock washers and (4) metric
screws (included with RAM mount bracket).
5. Re-attach ball mount to RAM mount bracket and tighten wing bolt to
secure.
Figure 11
Attach Terminal
Remove
ball mount
attachment
RAM Mount
Bracket
Loosen
wing bolt
RAM Ball
Mount
RAM MOUNT BRACKET INSTALLATION
The RAM mount bracket secures the terminal 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 terminal to the
desired position.
The terminal mounting kit includes the following:
•
•
•
•
•
•
16 / INSTALLATION
1 ram mount bracket
4 metric screws
4 SAE screws
4 hex nuts
4 washers #10
4 washers 1/4
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CAB TERMINAL BRACKET ASSEMBLY
1. Secure bracket to truck cab using 4 SAE screws (included).
2. Adjust terminal for ideal viewing by loosening/tightening the wing nut.
Figure 12
Cab Terminal Mount
Secure Ram mount
bracket (4) SAE Screws
Position terminal so that operator view is not obstructed and does
not interfere with tractor operation.
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INSTALLATION / 17
OPERATOR’S MANUAL
REMOTE SWITCH MODULE BRACKET KIT
The optional Remote Switch Module bracket kit allows mounting the switch
module to the armrest. This kit is available separately and can be ordered
by contacting the DICKEY-john Technical Support Group at
1-800-637-3302.
To install Bracket:
1. Place the rubber washer between the bracket base opening and the
side bracket opening aligning with the 1/4-20 nut.
2. Place bolt through the side bracket and washer to secure to the
bracket base.
3. Remove (2) screws from the flat surface of the armrest.
4. Align bracket base to the armrest holes and secure to the armrest with
the (2) screws.
5. Attach switch module to bracket as illustrated in (Figure 10).
Figure 13
Remote Switch Module Bracket Installation
Rubber
Washer
Secure
bolt
Remove armrest
screws, insert
bracket, re-attach
screws
18 / INSTALLATION
Flex4 Control System
11001-1576A-201601
OPERATOR’S MANUAL
SYSTEM HARNESS CONNECTIONS
The Flex4 control system connects to the truck cab harness and is powered
on and off when the ignition switch is powered on and off.
System harnessing connections include:
•
•
•
•
•
•
Cab harness
Rate control module harness
Output module harness
Optional extension harness
Optional electric motor/pump driver harness
Optional Road Watch Adapter and Flex4 interface cable
Figure 14
System Architecture with Electric Motor / Pump Driver and Optional Output Module Harness
Optional
Video Camera
Flex4 Terminal
467980507
GPS
Receiver
(optional)
CAN
Terminator
Wireless Module
(future release)
Rate Control Module
467985410S1
Output
module
466492101
Switch
Module
466495210
Extension Harness
466495060
Cab
Harness
466495051
Rate Control
Module Harness
466495071
Hydraulic
Valve
Output
Module
Harness
466495081
Gate Height
Sensor
Down
Pressure
Boom
Shutoff
Valve
Flex4
Interface
Cable
466495072
Battery
Temperature
Sensor
11001-1576A-201601
connects to
Rate Control
Module harness
Flow
Meter
Application Rate
Ground
Speed Control
Valve
Flex4 Control System
Electric Motor/
Pump Driver
466495430
Road
Watch
Adapter
INSTALLATION / 19
OPERATOR’S MANUAL
Figure 15
System Architecture with Electric Motor/Pump Driver Harness
Optional
Video Camera
Flex4 Terminal
467980507
GPS
Receiver
(optional)
CAN
Terminator
Wireless Module
(future release)
Rate Control Module
467985410S1
Switch
Module
466495210
Rate Control
Module Harness
466495071
Extension Harness
466495060
Cab
Harness
466495051
Connects to
Rate Control
Electric Motor/
Module Harness Pump Driver
466495430
Application Rate
Hydraulic
Valve
Flow
Meter
Ground
Speed
Control
Valve
Flex4 Interface
Cable 466495072
Gate Height
Sensor
Temperature
Sensor
Road
Watch
Adapter
Down
Pressure
Battery
20 / INSTALLATION
Flex4 Control System
11001-1576A-201601
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. Connect the power leads directly to the battery.
2. Connect the ignition wire to a switched +12VDC.
3. Connect the chassis ground lead to a bare point of the cab frame that
offers a good chassis ground connection.
4. Connect the CAN terminator, wireles module, switch module,
RoadWatch, and GPS, to their respective connectors on the cab
harness.
Figure 16
Cab Harness
Wireless
Module
(future
Switch
release) Module
To Extension Harness
Ignition or Rate Control
Module Harness
GPS
Receiver
Battery
To
Terminal
CAN
Terminator
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.
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INSTALLATION / 21
OPERATOR’S MANUAL
Figure 17
Rate Control Module Harness
Rate Control
Module
Cab or
Extension
Harness
PWM Ch 4 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
Terminator
Electric Pump
Driver Harness,
Extension Harness,
or Output Module
Harness
Digital 1 Sensor
Digital 2 Sensor
Hopper Level Sensor
Remote Blast
Ch2 Pressure/Bed Height (Analog 1)
Down Pressure Sensor (Analog 4)
Gate Height Sensor (Analog 3)
Remote On/Off
Flex4 Interface cable
attaches to any of the
analog 1-4 connectors.
RoadWatch Temperature
Sensor Adapter connects to
the Flex4 Interface cable.
Joystick
Scraper
Servo 1
Liquid
Tank Level Sensor (Analog 2)
Boom Section
Servo 2
Auxiliary
22 / INSTALLATION
Flex4 Control System
11001-1576A-201601
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 18
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 19
Extension Harness
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INSTALLATION / 23
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 20
Output Module Harness
Output Module
Electric Motor
Pump Driver
Harness
Rate Control
Module Harness
or Extension
Harness
Output 1
Output 2
Boom
Shutoff
Valves
Output 3
Output 4
Output 5
Output 6
Reverse Auger
Conveyor Left
Conveyor Right
+12V Switch Out
Gate Height
ELECTRIC MOTOR DRIVER HARNESS
Drives electric pumps or motors that draw high current (greater than 2
amps).
Figure 21
Electric Motor Driver Harness
To electric pump
Rate Control
Module Harness,
Extension Harness,
d l
24 / INSTALLATION
To PWM channel
(liquid or auxiliary)
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OPERATOR’S MANUAL
OPERATE SCREEN
The Operate screen has five main structured areas to display button
selections and operation functions that include:
1. Control channel application rate windows
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
NOTE: Large font on the Operate
screen indicates the control is
active. Small font indicates the
control is not active.
Figure 22
Operate Screen Layout
1
2
2
3
4
5
(1) CONTROL CHANNELS
Four control channels monitor granular and liquid applications and also
controls spinner speed.
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 sq ft/grams per sq/meter) (lbs/acre)
– Application of liquid material gallon (liters) per ton based on the
granular applications rate or gallons (liters) per mile (km) and
gallons (liters) per sq 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.
Flex4 Control System
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OPERATE SCREEN / 25
OPERATOR’S MANUAL
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 terminal that
correspond with screen text to provide screen navigation and quick
adjustment to system settings.
NOTE: Interchange Spread Width Bar
window with the Channel (Rate)
window by pressing the
terminal Home button.
(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.
(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 will 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
•
26 / OPERATE SCREEN
Ground speed is independent of product application and displays
actual ground speed in the lower display window. A manual ground
speed setting will also appear in this location, when enabled.
Flex4 Control System
11001-1576A-201601
OPERATOR’S MANUAL
•
Current time and date displays below the ground speed window.
DISPLAY SETTINGS (CAMERA/DISPLAY/ALARMS)
Display settings adjust the characteristics of appearance and volume of the
terminal:
•
•
•
Camera settings (appearance of the camera window display on the
terminal)
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 Page 2 button to display and 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; a
full bar graph indicates the highest volume. The volume level will
sound each time the increase/decrease arrows are pressed.
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OPERATE SCREEN / 27
OPERATOR’S MANUAL
Figure 23
Display Settings Screen
ABC
Adjustment
Buttons
A
Camera Window
1
6
2
7
Day/Night
3
Mode
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 terminal screen colors for better visiblity 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 24
Day and Night Mode Screens
Day Mode
28 / OPERATE SCREEN
Night Mode
Flex4 Control System
11001-1576A-201601
OPERATOR’S MANUAL
OPERATION
The Flex4 system powers on when the ignition switch is turned on. A
DICKEY-john startup screen and Flex4 screen displays for up to 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.
Figure 25
Powerup Screens
PRE-OPERATING CHECKLIST
The following procedures must be performed for effective operation:
•
•
•
NOTE: Channel and spread width
windows can be interchanged
on the Operate screen by
pressing the Home button
located on the lower right side
of the terminal.
Flex4 Control System
11001-1576A-201601
Perform System Response procedure for all granular, liquid, and
auxiliary channels
Calibration of ground speed sensor
Material application rates entered for each product to be applied
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.
OPERATION / 29
OPERATOR’S MANUAL
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 will be highlighted in
yellow.
2. With the selected channel highlighted, press either the Rate (-) or Rate
(+) until the desired rate displays.
NOTE: System setup is only accessible
when the system is stationary
with no ground speed.
Figure 26
Operate Screen
Auto enabled
with 0
ground speed
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 will appear on the display. A Blast rate will automatically shut
off if a time interval has been defined at the Blast Setup screen.
If a predefined time interval has not been set, Blast is turned off manually by
pressing the Blast button.
30 / OPERATION
Flex4 Control System
11001-1576A-201601
OPERATOR’S MANUAL
Figure 27
Blast Feature Enabled
BLAST
BLAST
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 28
Pause Feature Enabled
Flex4 Control System
11001-1576A-201601
OPERATION / 31
OPERATOR’S MANUAL
MATERIAL SELECTION
One granular, one liquid, and one auxiliary material can display
simultaneously on the console 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 will display in yellow.
4. When selected, press the Back button to return to the Operate screen.
Figure 29
Material Selection
GRANULAR
LIQUID
LIQUID
CALCIUM
SALT BRINE
MATRL 7
AUX
32 / OPERATION
MATRL 8
Flex4 Control System
11001-1576A-201601
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 30
Turning a Channel Off
Liquid channel
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 will display 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.
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OPERATION / 33
OPERATOR’S MANUAL
Figure 31
Unloading a Material
START
X
X
STOP
Ensure the area is clear prior to unloading to avoid possible injury.
34 / OPERATION
Flex4 Control System
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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 32
Manual Override
O.O
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.
Flex4 Control System
11001-1576A-201601
OPERATION / 35
OPERATOR’S MANUAL
NOTE: If manual mode is not
accessible, manual speed
access has been set to off in
the program mode.
Figure 33
Operate Screen with Manual Mode Enabled
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 rate
feedback sensor.
36 / OPERATION
Figure 34
Manual Control Channel Override
MANUAL
MANUAL
0.0
0.0
MANUAL
MANUAL
550
13.0
Flex4 Control System
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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 will display
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.
– Use the Back button to correct an incorrect passcode entry.
3. Press the Enter button to accept the passcode and display the
Operate screen.
Figure 35
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.
Flex4 Control System
11001-1576A-201601
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.
OPERATION / 37
OPERATOR’S MANUAL
Figure 36
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 61 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 37
Boom Section Control
Button indicates
action to occur
when pressed
38 / OPERATION
Flex4 Control System
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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.
Figure 38
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
•
Flex4 Control System
11001-1576A-201601
The Front/Rear Conveyor button toggles between front and rear
operation. A graphic indicates the current active state.
OPERATION / 39
OPERATOR’S MANUAL
Figure 39
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 40
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 41
Left/Right Spinner
LEFT
40 / OPERATION
RIGHT
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OPERATOR’S MANUAL
HYDRAULIC ACCESSORY TOOL OPERATION
To control an accessory tool during operation, press the Rate Increase/
Decrease buttons on the switch control 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 42
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:
•
•
•
•
•
•
•
Flex4 Control System
11001-1576A-201601
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
OPERATION / 41
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.
Figure 43
Total Screen
1
4
5
2
3
6
7
42 / OPERATION
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OPERATOR’S MANUAL
FLEX4 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.
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.
Access to menus using keyboard function keys include:
•
•
•
•
•
•
•
•
•
•
•
•
F1 Operate screen
F2 Granular Channel Setup
F3 Liquid Channel Setup
F4 Spinner Setup
F5 Auxiliary 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 will be required before a
driver begins operation or configuration setup screens are accessed.
Passcodes can be any combination of numbers up to 10 digits.
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OPERATOR’S MANUAL
USING THE KEYBOARD
Programming is performed when the truck is stationary and the system is
off.
1. Attach keyboard to terminal at the USB connection on the side of the
terminal.
Figure 44
USB Port
USB
port
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
changed by using the up/down
arrow keys on the keyboard to
highlight a function box .
Figure 45
Keyboard Layout and Functions
6
1
2
3
GRANULARGRANULAR LIQUID
APPL
OPERATE APPL
CONFIG.
RATE
RATE
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F2
F1
F3
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T
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SPINNER
F7
F6
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E
GROUND
SPEED
CAL
F5
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Q
LIQUID
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ACCUM
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7
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9
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44 / FLEX4 PROGRAMMING
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OPERATOR’S MANUAL
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.
Figure 46
Open a Text Window
Press ‘Enter’
to open
text
window
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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 will appear 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 47
Virtual Keyboard
Using the keyboard
up/down arrow
buttons select and
highlight a
parameter
Material
Label
46 / FLEX4 PROGRAMMING
Flex4 Control System
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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, will appear at top of the virtual keypad.
2. Press the Enter button to accept the label entry.
Figure 48
Virtual Keypad
2500.0
Number
Keypad
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OPERATOR’S MANUAL
48 / FLEX4 PROGRAMMING
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OPERATOR’S MANUAL
SYSTEM PROGRAMMING
The Flex4 Ice Control system has configuration screens to enter
user-defined rates, limits, and parameters for regulating system product
application. A keyboard is required for programming.
Four channels are available for material and spinner control:
•
•
•
•
(1) dedicated granular channel (F2)
(1) dedicated liquid channel (F3)
(1) dedicated spinner channel (F4)
(1) auxiliary channel to setup an additional liquid or granular channel
(F5)
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 anytime 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
Virtual Terminal Display settings
Current Totals screen
Refer to the Operation section for detailed function descriptions.
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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 is displayed 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.
Figure 49
Granular Channel Setup
STEP METHOD
50 / SYSTEM PROGRAMMING
RATE METHOD
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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/mift (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 will state Gate Low or Gate High. If Gate Low
displays, the signal from the sensor is exceeding the open voltage. In either
case, an alarm will activate. The Gate Height should be checked and set at
the granular calibration it was ran for on that granular channel.
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OPERATOR’S MANUAL
APPLICATION RATE METHOD
Two methods are available to control the application of material:
•
•
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.
52 / SYSTEM PROGRAMMING
7. Enter a desired blast rate that applies a higher-than-normal, spot
application when the Blast button is pressed during operation.
Figure 50
Step Method Screen
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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 51
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.
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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 52
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.
54 / SYSTEM PROGRAMMING
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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.
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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.
56 / SYSTEM PROGRAMMING
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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 53
Liquid Channel Setup Screen
Boom selection
only displays
when a channel
is set for liquid
or anti-ice
application.
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LIQ 1
LIQ 2
LIQ 3
LIQ 4
SYSTEM PROGRAMMING / 57
OPERATOR’S MANUAL
LIQUID RATE SETUP
Each material assigned to the liquid channel requires entry of material
parameters.
Figure 54
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
58 / SYSTEM PROGRAMMING
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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.
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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 55
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 minimim 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.
60 / SYSTEM PROGRAMMING
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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 56
Rate Method Enabled
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OPERATOR’S MANUAL
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.
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 57
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.
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SPINNER CONFIGURATION (F4)
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 Spinner Configuration screen, use the up or down arrow keys
on the keyboard to select and highlight the function box to enable or
disable.
2. Enter parameter values per below definition.
Figure 58
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.
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OPERATOR’S MANUAL
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.
PULSE FEEDBACK
Enable Pulse Feedback by selecting YES for closed-loop control. Disable
Pulse Feedback by selecting NO for open-loop control.
SPINNER CONSTANT
Spinner Constant establishes the number of pulses for one revolution of the
spinner. Spinner Constant appears only when Pulse Feedback is YES.
PWM OFFSET
PWM Offset identifies the minimum amount of PWM valve drive required to
start the liquid mechanism.
PWM SATURATION
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)
Regulate 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.
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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.
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 additional materials can be
added to the auxiliary channel.
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 59
Auxiliary Control Channel Screen
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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 60).
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 60
Accessory Sensors Screen
66 / SYSTEM PROGRAMMING
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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 61
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.
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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.
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Figure 62
Road Temperature Sensor
IMPORTANT: The RoadWatch(TM) temperature sensor or Surface
Patrol(TM) 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 Watch TM is a registered
trademark of Commercial
Vehicle Group TM. Surface
Patrol Technology is a
registered trademark of Control
Products Inc.
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Figure 63
Road Temperature Sensor Calibration
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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 RoadWatch(TM)
temperature sensor or Surface
Patrol(TM) 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 64
Air Temperature Sensor Screens
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 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.
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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 be displayed 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 65
Tank Level Sensor
PRESS C TO CAPTURE VOLTAGE
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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 66
Down Pressure
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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 67
Bed Height Sensor Screen
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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 68
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 69
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 70
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
Wireless Configuration (not currently functional)
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 71
System Setup Screen
BLAST SETUP
1. Press 1 on the keyboard to select Blast Setup.
Figure 72
Blast Setup Screen
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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 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 will fall.
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 73
Date and Time Screen
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OPERATOR’S MANUAL
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 74
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. 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 75
Software Version Screen
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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 76
System Reset 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 77
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 terminal:
•
•
•
•
•
•
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 78
GPS Sensor Screen
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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 if a 12V output signal is used.
Select Yes to control the left and right conveyor.
Select Yes to control raising and lowering the gate height from the cab.
Enter the increase/decrease PWM% that determines how fast the gate
opens and closes.
6. Enter the increase/decrease time that affects the speed of opening and
closing the gate.
Figure 79
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 is displayed on
the Operate screen.
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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 terminal 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 terminal 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 80
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 81
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 82
Truck ID Screen
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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 83
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 83) 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 will
be 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 84
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.
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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 85
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
DATA PASSCODE
8
3
IMPORT
DONE
9
4
0
5
6
YOU MUST REBOOT THE TERMINAL TO SAVE
ALL IMPORTED DATA
ENTER
REBOOT
TERMINAL
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 will
require re-entry of the passcode again to enter setup screens.
Disabling the passcode setting will reset the system allowing full access to
configuration screens.
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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 86
Route Configuration and Selection Screens
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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 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.
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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Figure 87
Operational Totals Screen
94 / SYSTEM PROGRAMMING
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LIFETIME TOTALS
Accumulated totals are displayed 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 88
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 94 for Drop Test and
Calibration procedures.
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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 / 97
OPERATOR’S MANUAL
Figure 89
System Response Calibration Screens
NOTE: Liquid pre-wet and anti-ice
channels have similar
calibration steps as granular.
98 / 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.
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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.
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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 (F) Accessory Sensor
screen before performing the drop test.
100 / CALIBRATIONS
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NOTE: Calibration Data Sheets are
available in back of this manual
to record constants.
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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 / 101
OPERATOR’S MANUAL
Figure 90
Granular Drop Test Procedure
102 / CALIBRATIONS
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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.
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.
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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 / 103
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.
104 / CALIBRATIONS
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Figure 91
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.
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OPERATOR’S MANUAL
AUXILIARY SYSTEM RESPONSE AND DROP TEST
An additional channel is 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
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 back of this manual
to record constants.
106 / CALIBRATIONS
A warning message indicates material will dispense when
procedure is started. Ensure all personnel are clear before
starting the next step.
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Figure 92
Spinner System Response Screens
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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 to start calibration.
Figure 93
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
108 / CALIBRATIONS
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an additional 4 times to calculate an average that appears on the
screen each time another calibration is ran.
8. After the final calibration, a calibration complete screen appears.
Press “D” to return to the main Calibration screen.
Figure 94
Spinner Spread Width
Enter measured spread
width into popup
window
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GROUND SPEED CONFIGURATION (F8)
Ground speed configuration sets the parameters for ground speed type and
performs a calibration.
Figure 95
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.
110 / CALIBRATIONS
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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.
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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 96
Ground Speed Calibration Screens
112 / CALIBRATIONS
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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.
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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 / 113
OPERATOR’S MANUAL
114 / CALIBRATIONS
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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 terminals
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 97
Passcode Screen
1
7
2
ENTER CONFIGURATION
DATA PASSCODE
8
3
IMPORT
DONE
9
4
0
5
6
YOU MUST REBOOT THE TERMINAL TO SAVE
ALL IMPORTED DATA
ENTER
REBOOT
TERMINAL
BACK
NOTE: USB memory device must be
inserted into the terminal before
the Import/Export button
appears.
EXPORT CONFIGURATION AND LOG DATA FILES
To export Configuration Files:
1. Insert USB memory device into side of terminal.
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 will
contain the configuration files.
5. Press the Export Now button. A Data Export Done screen indicates
file transfer is complete.
EXPORT FILE STRUCTURE
To export Log Data Files:
Log data files are exported following the same procedure as exporting
configuration files (select Data USB Export button). Log data files can be
imported to a reporting software tool to create truck fleet reports.
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OPERATOR’S MANUAL
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: Flex4_DataFolder/Flex4_42067_2011-09-14_15-00-39
Figure 98
Exporting Configuration Files
IMPORT/EXPORT
CONFIG
USB
IMPORT
CONFIG
USB
EXPORT
DATA
USB
EXPORT
CONFIGURATION
LOGGED DATA
BACK
EXPORT TO USB
CONFIGURATION
FILE NAME:
Dj_Flex4_Settings_42067.xml
Logged Data Files Export in Progress
EXPORT
NOW
BACK
DATA
EXPORT
DONE
BACK
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IMPORT CONFIGURATION FILES
To import Configuration Files:
1. Insert USB memory device into side of terminal.
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. Use the terminal keys to select the choices.
– A Data Import screen indicates file(s) are uploaded to terminal.
Figure 99
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
USE TERMINAL KEYS TO SELECT DATA
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BACK
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OPERATOR’S MANUAL
6. Press the Reboot Terminal button to turn the system off and on again
to accept imported data.
Figure 100
Reboot Terminal
DATA
IMPORT
DONE
YOU MUST REBOOT THE TERMINAL TO SAVE
ALL IMPORTED DATA
REBOOT
TERMINAL
BACK
118 / IMPORT/EXPORT DATA FILES
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DIAGNOSTICS
Diagnostic screens (F7) can be used to check system performance by
displaying sensor input readings that connect to the terminal, control
module, and output module that could indicate potential issues.
Three Diagnostic screens are available and selected based on where the
sensor is connected:
•
•
•
Terminal (joystick inputs)
Control module (control channels, spinner, auxiliary sensors)
Output module (added accessories)
PERFORM A DIAGNOSTICS CHECK
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.
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OPERATOR’S MANUAL
Figure 101
Enable Manual Ground Speed
O.O
O.O
Increase/
decrease
manual
speed
To Perform a Diagnostics Check:
1. Press the appropriate number on the keyboard to select the terminal,
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 102
Main Diagnostic Screen
120 / DIAGNOSTICS
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TERMINAL
The Terminal screen indicates the current state of the joystick inputs
connected to the terminal 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 103
Terminal Diagnostics Screen
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, auxiliary), spinner, or
accessory sensor to perform the relevant diagnostic check.
Figure 104
Control Module Diagnostics Screen
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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:
–
–
–
–
122 / DIAGNOSTICS
Solenoid Power
Solenoid Ground
ECU Power
ECU Ground
Flex4 Control System
11001-1576A-201601
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 105
Spinner Diagnostics
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 Control System
11001-1576A-201601
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 / 123
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 106
Accessory Sensor Diagnostics
124 / DIAGNOSTICS
Flex4 Control System
11001-1576A-201601
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 actual
function could indicate the
Figure 107
Output Module Diagnostics Screen
Accessory
Buttons
Flex4 Control System
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DIAGNOSTICS / 125
OPERATOR’S MANUAL
126 / DIAGNOSTICS
Flex4 Control System
11001-1576A-201601
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 Control System
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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
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.
201
Set Point Alarm
A negative setpoint has been calculated which is
not a normal occurrence causing an error.
Check channel parameters and perform the
appropriate material valve calibration (liquid,
granular or auxiliary) at the F6 calibration screen.
206
In Manual Alarm
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
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.
128 / TROUBLESHOOTING
Flex4 Control System
11001-1576A-201601
OPERATOR’S MANUAL
ERROR
CODE
208
ERROR
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.
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.
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.
Flex4 Control System
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TROUBLESHOOTING / 129
OPERATOR’S MANUAL
ERROR
CODE
ERROR
PROBABLE CAUSE
510
Road Temp Below Alarm
Value 3
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.
608
Ground Low Voltage
1. Damaged/shorted actuator harness
2. Defective PWM valve driver or Servo valve
driver.
3. Defective module.
1. Inspect actuator harness for damage around
the PWM and Servo valve connections. Repair or
replace harness.
2. Inspect PWM or Servo valve drivers for
damage and replace if necessary.
3. Inspect module for damage and replace if
necessary.
609
Ground High Voltage
Ground offset has drifted high.
1. Check vehicle grounding.
130 / TROUBLESHOOTING
Temperature has dropped below alarm threshold.
CORRECTIVE ACTION
1. Adjust alarm setting.
2. Check sensor.
1. Adjust alarm setting.
2. Check sensor.
1. Adjust alarm setting.
2. Check sensor.
Flex4 Control System
11001-1576A-201601
OPERATOR’S MANUAL
APPENDIX A 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 Control System
11001-1576A-201601
10
9.5
= 1053
APPENDIX A CONVERTING CONSTANTS / 131
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 x B
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
132 / APPENDIX A CONVERTING CONSTANTS
Flex4 Control System
11001-1576A-201601
Dealers have the responsibility of calling to the attention of their customers the following
warranty prior to acceptance of an order from their customer for any DICKEY-john product.
DICKEY-john® WARRANTY
DICKEY-john warrants to the original purchaser for use that, if any part of the product
proves to be defective in material or workmanship within one year from date of original
installation, and is returned to DICKEY-john within 30 days after such defect is discovered,
DICKEY-john will (at our option) either replace or repair said part. This warranty does not apply
to damage resulting from misuse, neglect, accident, or improper installation or maintenance; any
expenses or liability for repairs made by outside parties without DICKEY-john’s written consent;
damage to any associated equipment; or lost profits or special damages. Said part will not be
considered defective if it substantially fulfills the performance expectations. THE FOREGOING
WARRANTY
IS
EXCLUSIVE
AND
IN
LIEU
OF
ALL
OTHER
WARRANTIES
OF
MERCHANTABILITY, FITNESS FOR PURPOSE, AND OF ANY OTHER TYPE, WHETHER
EXPRESS OR IMPLIED. DICKEY-john neither assumes nor authorizes anyone to assume for it
any other obligation or liability in connection with said part and will not be liable for
consequential damages. Purchaser accepts these terms and warranty limitations unless the
product is returned within fifteen days for full refund of purchase price.
For DICKEY- john Service Department, call
1-800-637-3302 in either the U.S.A. or Canada
Headquarters:
5200 Dickey-john Road, Auburn, IL USA 62615
TEL: 217 438 3371, FAX: 217 438 6012, WEB: www.dickey-john.com
Europe:
DICKEY-john Europe S.A.S, 165, boulevard de Valmy, 92706 – Colombes – France
TEL: 33 (0) 1 41 19 21 80, FAX: 33 (0) 1 47 86 00 07 WEB: www.dickey-john.com
Copyright 2016 DICKEY-john Corporation
Specifications subject to change without notice.
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