Dickey John Control Point Service Manual

Dickey John Control Point Service Manual
Table of Contents
Control Point System Overview……………………………………………………3
Operation……………………………………………………………………………8
Programming……….……………………………………………………………...11
Calibration…………………………………………………………………………29
Troubleshooting……………………………………………………………………35
System Response Description……………………………………………………..40
Appendix A………………………………………………………………………...44
Appendix B………………………………………………………………………...46
Appendix C………………………………………………………………………...47
Appendix D………………………………………………………………………...50
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CONTROL POINT® SYSTEM OVERVIEW
The DICKEY-john® Control Point® is a closed loop control system used for simultaneously controlling the
spreading of granular and liquid ice-control materials in conjunction with ground speed. The system has been
designed to work with a variety of actuators including drop on actuators (servo valves), pulse width modulated
valves, electric pumps, and motorized ball valves. The liquid channel has also been designed with enough
flexibility that it can be configured to apply pre-wetting material (based on granular output) or multiple boom
configurations such as anti-ice material, roadside vegetation material, dust control material, etc. Another key
feature of the Control Point® is the open loop control of the spinner speed for adjusting the spread width on the
go.
The Control Point® system consists of six basic components:
(1)
(2)
(3)
(4)
(5)
(6)
Console
Switch Module
Ground speed sensor
Feedback devices to monitor application rates
Actuator devices to regulate application rates
Harnesses to interconnect all system devices
The detachable keyboard (optional), DjDART – handheld data transfer tool, and PC (not provided) are considered
programming and reporting aids, which are not part of the basic Control Point system.
1. Console
The console has a large 160 X 128 dot-matrix LCD display and a single pushbutton switch for controlling system
power and cycling through the Operator screens. All programming and calibrations screens are menu driven with
the use of an external keyboard creating a simple and easy to use system. An operator can view granular and
liquid application rates, ground speed, spread width and time/date simultaneously.
2. Switch Module
The operator controls the real-time functions of the Control Point® system with the switch module. The switch
module has the following seven switches:
OFF/AUTO/UNLOAD (Master Switch) - AUTO causes the application rates of the activated product channels
to be controlled when the vehicle is moving and ground speed is sensed. Setting the switch to UNLOAD
while the vehicle is stopped causes the activated product channels to dispense at the maximum
conveyor/auger speed and liquid flow rate. OFF prevents spreading of materials except for blasting (which
can also be performed in AUTO).
WARNING:
IF THE SPINNER IS PROGRAMMED TO WORK DURING 'UNLOAD', BE
SURE THAT NO ONE IS IN THE VICINITY BEFORE PRESSING 'UNLOAD' TO AVOID
THE POSSIBILITY OF PERSONAL INJURY!
Granular ON/OFF - Activates the granular channel for real-time control (when the Master Switch is in AUTO).
Granular INC/DEC - Increases and decreases the granular application rate. It is also used to choose between
enabled granular materials when MATERIAL SELECT screen is displayed. This toggle switch functions
only when the Granular ON/OFF channel switch is ON.
Liquid ON/OFF - Activates the liquid channel for real-time control (when the Master Switch is in AUTO).
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Liquid INC/DEC - Increases and decreases the liquid application rate. It is also used to choose between enabled
liquid materials when MATERIAL SELECT screen is displayed. This toggle switch functions only when the
Liquid ON/OFF channel switch is ON.
WIDTH ADJUST - This twenty-position, rotary knob adjusts spinner speed, which directly determines granular
SPREAD WIDTH. The knob dial shows each 20% interval, with maximum spinner speed corresponding to
the fully clockwise (100%) setting.
BLAST - Pressing this button switch activates the Blast application rate (with the Master Switch either in AUTO
or OFF.)
The switch module harness plugs into the console and contains the connectors for both keyboard and PC interface.
An RS-232 port connector, located on the Switch Module harness, permits data transfer to and from the Console.
This port interfaces to a PC to upload system constants and configuration information. Also, accumulator values
and report information, including vehicle and driver identification, are downloaded.
3. Ground Speed Sensor
The ground speed sensor generates pulses proportional in frequency to the vehicle ground speed. This sensor is
vital to the operation of the system because true vehicle ground speed must be known to ensure accurate product
application. The system functions with a wide variety of electronic and mechanical speedometer sensors.
4. Feedback Devices
The feedback devices are sensors, which generate pulses proportional in frequency to the product application rate
and spinner speed. Several types of sensors can be used with the Control Point® system including photo-electric,
hall-effect shaft sensors, flowmeters, and potentiometer position sensors.
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5. Actuator Devices
Either servo valve actuators or proportional valves (PWM) are used to regulate oil flow to hydraulic motors, which
drive the conveyor/auger, liquid pump, and spinners. Versions 6.30 and later provide PWM output only for
granular and spinner channels. The liquid channel of Control Point can control either a hydraulic valve or a 12volt DC motor.
6. Harnesses
The main harness assembly connects the console to the ground speed sensor, feedback sensors, channel valve (or
DC motor) actuators, vehicle battery, ignition, and additional optional connections (including two speed axle,
hopper level sensor, Road Watch temperature sensor, material flow sensor, tank level sensor, gate height sensor,
and boom sense inputs). An optional Extension Harness, which allows the Main Harness to extend outside the
cab, contains duplicate connectors to permit maximum hook-up flexibility.
Keyboard (Optional)
The console is programmed with the use of a keyboard, which can be removed from the truck after the
programming is complete, eliminating the need of lock out codes or keys.
Function Keys
Identifies each function
Number Keys
Select parameters
from screen list
Alpha Keys
Used for labels
Used to make selections
Key Functions
• F1 Operate screen
List of material, Speed and Spread width.
• F2 Granular Application Rate
Adjust application rates for a granular material (Salt, Sand and Mix A or B)
• F3 Granular Configuration
Adjustable configuration of granular channel.
• F4 Liquid Application Rate
Adjust application rates for a liquid material.
• F5 Liquid Configuration
Adjustable configuration of liquid channel.
• F6 Calibration
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•
•
•
•
•
•
Calibration procedure for each material.
F7 Ground Speed
Calibration and Configuration.
F8 Spinner Configuration
Adjustable configuration of spinner.
F9 Accumulator
Checks accumulation of material.
F10 System Information
Displays Alarm History, System Totals, On/Off History, Rate Change History and Truck ID.
F11 System Response
Runs system response for liquid and granular channels and spinner control.
F12 Miscellaneous
Access to Blast Setup, Time/Date, System Units, Serial Port Configuration, Change
Language/Keyboard, Gate Height Configuration, Road and Air Temerature Configuration, 12V
boom output configuration, down pressure sensor, bed height alarm, and Service Menu
Hopper Level Sensor (Optional)
The granular material in the bed of the spreader vehicle interrupts the optical light beam of this low-level sensor.
When the material level falls beneath the sensors mounting level, a repetitive beep sounds and an appropriate
message appears in the warning/alarm area of the OPERATE screen.
Tank Level Sensor (Optional)
This sensor is used to monitor the liquid level for the pre-wet or anti-ice systems. The tank level sensor feature
must be enabled in the Control Point console before it will be active. It can be enabled for only one of the four
liquid materials being used. When enabled, a bar graph and a digital readout representing the tank level will be
displayed. If granular is enabled, the spinner bar graph will share its portion of the operate screen with the tank
level bar graph.
Gate Height Sensor (Optional)
This sensor will allow the granular system to be more accurate by adjusting the conveyor speed to meet the
application rate based on the current gate height. The gate height sensor is to be connected to the main harness
lead labeled GATE on the new harness and PRESSURE on the old harnesses. The new 6.3 software has removed
pressure control from the Control Point and utilizes the pressure sensor input for the gate height. If you have a
pressure controlled liquid system you can not connect the gate height sensor. When enabled, the gate height will
be displayed to the nearest .1 in or 1 cm in the lower right corner of the operate screen. The configuration and
calibration of the gate height sensor is found under Miscellaneous (F12), More (6), Gate Height Sensor (1).
Road Temperature Sensor (Optional)
This sensor is used to monitor the road temperature and notify the driver of road temperature changes. There are
three temperature alarm settings that can be set to alert the operator. When enabled, the road temperature will be
displayed in the lower left side of the operate screen. The configuration for the road temperature sensor is found
under Miscellaneous (F12), More (6), Road Temperature Sensor (2).
Air Temperature Sensor (Optional)
This sensor is used to monitor the air temperature and notify the driver of air temperature changes. There are three
temperature alarm settings that can be set to alert the driver. When enabled, the air temperature will replace the
date in the lower left side of the operate screen. The configuration for the air temperature sensor is found under
Miscellaneous (F12), More (6), Air Temperature Sensor (3).
Down Pressure Sensor (Optional)
The down pressure sensor is designed to allow the operator to view the relative pressure applied to the belly
scraper. The sensor uses the same input as the tank level sensor. Both the tank level and the down pressure
sensor cannot be configured or used at the same time. When enabled, a bar graph with a digital percentage
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readout representing the down pressure will be displayed. By enabling the down pressure sensor the tank level, if
enable, is automatically disabled. If granular is enabled, the spinner bar graph will share its portion of the Operate
screen with the down pressure bar graph. The configuration and calibration for the down pressure sensor is found
under Miscellaneous (F12), More (6), Down Pressure Sensor (5).
Bed Height Sensor (Optional)
This sensor will inform the operator when the bed has exceeded its recommended operating height.
The operator must inspect and maintain all mechanical linkage of the sensor on a regularly scheduled
interval to insure proper operation of the bed height alarm. Visual inspection of the bed height must still
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 failure of the alarm to indicate an unsafe operating height.
Since the bed height sensor uses the same input as the gate height sensor, both sensors cannot be configured
at the same time. If the gate height is configured and the bed height sensor is enabled, the gate height sensor will
automatically be disabled. The bed height sensor feature must be enabled in the Control Point console before it
will be active. It can be enabled through the miscellaneous menu and will function regardless of material
selection. The configuration and calibration for the bed height sensor is found under Miscellaneous (F12), More
(6), Bed Height Sensor (6).
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OPERATION
This section explains how the operator (driver) of the ice-control vehicle uses the controls on the switch module
and console of the Control Point® system to access the necessary screens and perform the operator functions. The
detachable keyboard is required only when programming or calibrating the system.
The operator can observe three or four different screens, depending upon programming. The main operator screen
is called the OPERATE screen and the remaining screens are named CURRENT TOTALS, SEASON TOTALS,
and MATERIAL SELECT. The last of these screens does not appear unless the conditions indicated below, under
the heading “Material Select Screen”, are met.
Operate Screen
The OPERATE screen displays information pertaining to the three control channels (granular, liquid, and
spinner), ground speed, boom status, date, and time of day. For ease of viewing, partitions referred to as
“windows” are used to separate this information. In addition, warning messages appear if operator or system
errors are detected.
If either product channel ON/OFF switch (on the Switch Module) is OFF, “OFF” is displayed in the “window” for
that channel. When the product channel switch is ON, the name of the selected material and its target application
rate (APR) are shown.
The granular channel is displayed in the left window, the liquid channel in the middle window, and the ground
speed in the right-hand window. When the vehicle begins moving and ground speed is detected, the actual ground
speed in miles per hour (MPH) is displayed.
6
2
3
1
4
5
8
7
Operator Controls
1.
Power Button - Round button located on the front right side of the display console. This is the only switch
on the display console, all other switches are on the switch module.
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2.
Master Switch - This switch is located on the switch module. The switch is located on the top of the switch
module and has three positions. It consists of off , automatic and unload positions.
3.
Blast - The "red button", it provides the spreader to run at the programmed blast rate.
4.
Granular INC/DEC (+/-) Switch - This switch is used to change the preprogrammed application rates in the
direction indicated by the switch. This is the upper left switch on the switch module.
5.
Granular ON/OFF Switch - This turns the granular channel on or off. This is the lower left switch on the
switch module.
6.
Liquid INC/DEC (+/-) Switch - This switch is used to change the preprogrammed application rates in the
direction indicated by the switch. This is the upper right switch on the switch module.
7.
Liquid ON/OFF Switch - This turns the liquid channel on or off. This is the lower right switch on the switch
module.
8.
Spread Width Knob - This knob adjusts the spinner speed. It is the bottom knob on the switch module.
Operation
Automatic Mode (Used to Spread Material)
1. Set spreader master switch to off and turn on the power button. Briefly press this button to turn the system
on. To turn off, hold this button in until a beep sounds (approximately 3 seconds) and the screen text will
dispappear.
2.
The desired material type may be selected by setting the masteer switch in the off position, assuring zero
ground speed, and then briefly pressing the power button on the console until a list of granular materials
(SALT, SAND, MIX A, MIX B) appears on the display screen. The granular INC/DEC (+/-) switch should
be used to change the pointer to the desired material type. To return to the Operate screen the power button
must be depressed again.
3.
The desired application rates for both granular and prewet can be set by using the individual INC/DEC
switches.
4.
To begin spreading turn the granular and liquid on/off switches to the desired position and then set master
switch to automatic. If necessary, set the spread width knob to desired speed. Spreading begins when the
truck starts moving and stops when the trucks stops moving. The master switch can be used to turn the ice
control system on and off as well.
Blast
Pushing the red blast button on the left side of the switch module forces the spreader to operate at the
preprogrammed blast rate. This function is active for both stationary and moving vehicle conditions when the
master switch is in the Auto or Off position. The Blast rate is programmed for a particular application rate/mile
and may be set for a time interval. If a preprogrammed Blast time has not been set, you must hold the Blast button
to Blast.
Unload
Pressing the master switch in the unload position causes the spreader to run at full capacity. The unload function
can not be accessed when the vehicle is moving. The unload function can be turned off by switching the master
switch to off. The spread width knob is used to set the speed of the spinner.
Current Totals Screen
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From the operate screen, press and release the console button after the beep. Press a second time, if necessary, to
display the CURRENT TOTALS screen. The master switch must be in the off position. The current totals screen
appears showing the totals accumulated for the current product selected. To see other totals, return to the
MATERIAL/MANUAL SELECT screen and select those products.
Note: This function can be used to report material usage during a shift or storm.
Clearing The Current Totals Screen (If enabled)
With the granular switch on, and the ground speed at zero, press the Granular (+/-) switch up and release when the
beep sounds. A message "PRESS DEC TO CONFIRM CLEAR (product) ACCUMULATORS" appears. Next,
press the same switch down (DEC) and the totals reset to zero. The same procedure is used on the liquid
accumulators by using the Liquid (+/-) swithc. Do the same for each material type as needed. To enable clearing
the current totals please refer to page 19.
Season Totals Screen
From the operate screen, press and release the console button after the beep. Repeat until the SEASONS TOTAL
screen appears. This shows the amount of material applied, miles traveled and hours elapsed for the season. The
totals can only be cleared in the program mode using a keyboard.
Display Warnings and Alarms
Alarm messages appear in the middle of the screen on the display console. The message will list the error type
and location of error.
Manual Override
The control system has an automatic override function, which occurs in the event of a loss of the feedback sensor.
Under this condition, the system automatically reverts to a MANUAL mode to continue spreading material until
the problem is corrected (i.e. after the storm or until a replacement part is received).
Calibration
Calibration is done by a catch test for each type of material programmed. This must be done using a keyboard in
the calibrate function mode of the Control Point® unit.
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PROGRAMMING
Programming of the Control Point® system consists of the keyboard entry of calibration constants, configuration
parameters (sensor and actuator specifications), granular and liquid material information, and product application
rates (APRs). It also includes the resetting of system accumulators for vehicle mileage, material usage, and time
totals. All programming should be completed prior to calibration.
NOTE: The vehicle must be stationary and the Master Switch in the OFF position for all
programming.
Keyboard and Screen Considerations
On-screen, menu-driven instructions and the use of a standard keyboard make programming and calibration, easy
& efficient. The keyboard can be detached and removed from the truck after the system has been programmed and
calibrated, eliminating the need for lockout codes or keys.
The keyboard has a decal affixed above the Function Keys Fl through F12 to identify access to the following
functions:
Fl - Operate Mode
F2 - Granular Application Rates
F3 - Granular Configuration
F4 - Liquid Application Rates
F5 - Liquid Configuration
F6 - Calibration
F7 - Ground Speed
F8 - Spinner Configuration
F9 - Accumulators
F10 - System Information
Fll - System Response Calibration
F12 - Miscellaneous
When a screen containing parameters first appears, an "index" arrow is positioned to the left of the first
item and the first digit of that parameter is underscored. The up arrow and down arrow keys move the
index to other parameters. To change the indexed parameter, type in the desired value, then press the
ENTER key. Unless ENTER is pressed, the new value is not stored (except for YES/NO and serial port
configuration selections).
The Backspace key erases incorrectly typed numbers or characters. To restore a previously stored value after
typing in a new number, press either arrow key before pressing ENTER. Invalid keystrokes are not accepted for
entry and cause an audible warning.
Pressing the ESC key causes a return to the previously displayed screen unless a function key (Fl through F12)
has just been pressed. If MORE..." appears at the bottom of a screen, additional parameters are shown on the next
screen which can be reached by moving the "index" arrow to "MORE...". Similarly, if "MORE..." appears at the
top of a screen, a related previous screen can be reached by moving the "index" to "MORE..."
Fl - OPERATE MODE
Pressing Fl causes the OPERATE screen to appear. While no programming functions can be performed
from this screen, it may be used to observe this screen (or the other three operator screens, accessible by
pressing the Console button) to verify proper programming.
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F2 - GRANULAR APPLICATION RATES
The granular application rates screens display the application rate parameters for each granular material
used. These parameters specify material application rates (APR) and application rate steps. The preprogrammed values for these parameters are usually the same for all granular materials. Each screen for
all granular material used should be viewed and verified or reprogrammed its APP RATE parameters
satisfy the APR requirements.
Press F2 to obtain the (GRANULAR) APPLICATION RATES screen. The names of four (4) granular
materials are shown, each followed by the word ENABLED or DISABLED (defined in next paragraph).
Press the number corresponding to the material to obtain its APP RATES screen. For example, press 1
for the SALT APP RATES screens.
A. Enable - Entering a Y (YES) following ENABLE on a particular granular APP RATES screen
causes that material to appear on the MATERIAL SELECT screen, allowing the operator to select it for
use.
Any or all of the four different granular materials can be individually enabled by the supervisor for
possible selection and application by the operator. It is possible to program (and calibrate) all product
materials without enabling them. Enabling and disabling can be done at any time by the supervisor.
B. Step Method - The console may be programmed using either of the two methods to specify and
program application rates (APRs) - the Step Method or the Rate Method. Since these perform essentially
the same function, the choice is a matter of personal preference.
The Step Method requires specifying values for an initial or start-point APR (APP START), an
increase/decrease step rate (IC/DC STP), a minimum APR limit (MIN APP), and a maximum APR limit
(MAX APP). This method is selected by using the arrow keys to position the index arrow next to STEP
METHD, then pressing Y (YES).
The RATE Method allows the supervisor to program up to ten (10) different APRs - RATE 1 through
RATE 10. If less than ten rates are programmed, the supervisor must enter a zero (0) value for the rate
immediately following the last one programmed. The initial rate displayed in the OPERATE mode after
programming is RATE 1. The operator can cycle through other rates (by pressing the " +/-" switch on the
Switch Module) either before or after beginning to apply the material. This method is selected by
entering N (NO) for STEP METHD.
Changing from one of the above APR selection methods to another for any particular material (by
changing STEP METHD from YES to NO or vice versa) automatically causes all rates from the previous
method to be cleared out.
C. APP START - See "B. Step Method" above.
D. IC/DC STP - See "B. Step Method" above.
E. MIN APP - See "B. Step Method" above.
F. MAX APP - See "B. Step Method" above.
G. Blast Rate - With either above APR selection method, a higher than normal, spot-application rate can
also be programmed. The operator activates this blast rate (BLST RATE) by depressing the red BLAST
button on the left side of the Switch Module.
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H. Channel Label - Any product material name (CHNL LBL) of nine (9) characters or less can be
entered. Pressing the ENTER key stores the new name and causes it to appear on all granular screens
and the OPERATE screen when that material is selected.
I. Other Granular Materials - If all granular materials to be used are not yet programmed, press F2 to
return to the (GRANULAR) APPLICATION RATES screen. Select and program the next material.
F3 - GRANULAR CONFIGURATION
Configuration parameters specify the types of actuators and sensors used and their performance
specifications. To prepare for calibration of the system the following granular configuration parameters
for each of the granular materials used should be verified or reprogrammed. These parameters do not
change unless the system hardware changes or the related calibration routines are rerun.
Press F3 to obtain the (GRANULAR) CONFIGURATION screen. The names of four (4) granular
materials are shown - the same names as on the (GRANULAR) APPLICATION RATES screen. Press
the number corresponding to the desired material to obtain its (GRANULAR) CONFIGURATION
screen. For example, presses 1 to obtain the SALT CONFIGURATION screen.
A. Spreader Constant
The first parameter on the (GRANULAR) CONFIGURATION screen, spreader constant (SPR CON), is
defined as the number of pulses generated by the application rate sensor (monitoring the speed of a
rotating shaft in the conveyor/auger mechanism) per pound of granular material discharged from the
spreader. The units are pulses per pound (P/LB).
The spreader constant differs for each granular material, spreader vehicle, and feed-gate height setting
(for V-box spreader gates only).
B. Servo/Proportional Drive
The parameter called servo drive (SRVO DRV) asks the question "Does the granular channel use a
servo-controlled valve?" If a proportional valve is used, the answer is NO. This feature is available on
version 5.10 and earlier. Control Point version 6.30 and later support proportional valves only for
granular control.
C. Drive Frequency
The parameter DRV FREQ is the valve manufacturer's suggested drive frequency, as shown on the valve
specification sheet. The rated drive frequency for the DICKEY-john® servo valve is 100 Hz.
D. PWM Offset (Granular)
The PWM OFFSET parameter appears on this screen regardless of whether a servo or proportional valve
is used. It defines the starting point of the valve operating range, i. e., the valve position at which the
conveyor/auger starts moving. This parameter value is determined automatically for the granular channel
during the GRANULAR SYSTEM RESPONSE routine (Fll-l).
E. PWM Saturation (Granular)
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The PWM Saturation (PWM SAT) parameter appears on this screen only if a proportional valve is
specified. It defines the end point of the valve operating range, i. e., the valve position at which
maximum conveyor/auger operating speed is reached. This parameter value is determined automatically
for the granular channel during the GRANULAR SYSTEM RESPONSE routine (Fll-l).
F. System Response
The following paragraphs on the SYSTEM RESPONSE calibration constants (SYS RSPNS, VALV
BOOST, PWM OFFSET, and PWM SAT) are for descriptive purposes only. That is, since these
parameters are automatically determined during the GRANULAR SYSTEM RESPONSE calibration
routine, the values displayed for these parameters can be ignored during programming. This routine
should always be performed, regardless of whether any other calibration routines need to be run.
The SYSTEM RESPONSE constant, SYS RSPNS, adjusts the response of the control system to the
hydraulic and mechanical systems of the granular control channel on each particular spreader vehicle.
The value of this parameter is determined automatically during the GRANULAR SYSTEM RESPONSE
calibration routine (Fll-l). This constant can be fine-tuned later for optimum performance by keyboard
entry as explained Appendix A.
G. Valve Boost
The valve boost constant, VALV BOOST, increases the amount of system gain initially applied to the
granular control channel to cause it to reach final operating speed (i. e., the target APR) as quickly as
possible. The value of this parameter is determined automatically for the granular channel during the
GRANULAR SYSTEM RESPONSE routine (at the same time the SYSTEM RESPONSE constant, SYS
RSPNS, is determined). This constant can be fine-tuned later for optimum performance by keyboard
entry as explained in Appendix A.
H. A Filter
The parameter AFILT is a feedback filter constant determined automatically during the SYSTEM
RESPONSE calibration routine. This parameter minimizes the effects of electrical noise and mechanical
vibrations on the feedback signal. The smaller the number the greater the degree of filtering. The value
of this parameter can be changed manually as described under the heading "Fine-tuning System Response
Parameters" in Appendix A.
I. Other Granular Materials
If all granular materials to be used are not yet programmed, press F3 to return to the (GRANULAR)
CONFIGURATION screen and select the next material to be programmed. Enter any known spreader
constants for the remaining granular materials and verify the servo drive and drive frequency parameter
values (SRVO DRV and DRV FREQ) are identical for all granular materials.
F4 - LIQUID APPLICATION RATES
The liquid application rates screens display the application rate parameters for each of the liquid
materials used. These parameters specify APR rate steps and limits. The pre-programmed values for
these parameters are usually the same for all liquid pre-wet materials and the same for all liquid anti-icing
materials. The supervisor must view the screen for each liquid material used, then verify or reprogram its
APP RATE parameters, as required, to satisfy the APR requirements.
Press F4 to obtain the (LIQUID) APPLICATION RATES screen. The names of four (4) liquid materials
are shown, each followed by the word ENABLED or DISABLED. Press the number corresponding to
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the material to be programmed to obtain its liquid APP RATES screen. For example, presses 1 for the
LIQUID 1 APP RATES screen.
See the heading "F2 - GRANULAR APPLICATION RATES for descriptions of all parameters on the
(LIQUID) A.PP RATES screens, substituting "liquid" for "granular" and changing APR units to GAL/
TON. (If the liquid channel is "channel dependent" (defined later under the heading "F5 - B. Channel
Dependence"), APR units are GAL/MILE instead.) The parameter DENSITY does not apply to liquids.
If all liquid materials to be used are not yet programmed, press F4 to return to the (LIQUID)
APPLICATION RATES screen. Select and program the next material to be used.
F5 - LIQUID CONFIGURATION
Configuration parameters specify the types of actuators and sensors used and their performance
specifications. To prepare for calibration of the system the following liquid configuration parameters for
each liquid material used should be verified or reprogrammed. These parameters do not change unless
the system hardware changes or the related calibration routines are rerun.
Press F5 to obtain the (LIQUID) CONFIGURATION screen. The names of four (4) liquid materials are
shown - the same names as are shown on the (LIQUID) APPLICATION RATES screen. Press the
number corresponding to the desired material to obtain its (LIQUID) CONFIGURATION screen. For
example, presses 1 to obtain the LIQUID 1 CONFIGURATION screen.
A. Pre Wet
The first parameter on this screen, is the Pre Wet selection. When this parameter is enabled or set to
YES, the liquid material becomes dependent on the granular material.
The output rate of the liquid channel is made dependent upon the granular output rate by entering Y
(YES) after PRE WET on the LIQUID CONFIGURATION screen. Notice that, when the PRE WET is
set to (NO), the units for its application rates, shown on its LIQUID APP RATES screen (and on the
OPERATE screen), change from GAL/TON to GAL/ MILE, reflecting its independence from the
granular APR.
B. Flow meter Constant
The first parameter on this screen, the flow meter constant (K-FACTOR), is defined as the number of
pulses generated by the application rate sensor (the flow meter) per gallon of liquid dispersed from the
spray bar or boom (for pre-wet and anti-icing liquids respectively). Its units are pulses per gallon
(P/GAL).
The K-FACTOR is stamped on the flow meter body. This number can be considered sufficiently
accurate for keyboard entry if the viscosity of the liquid is very nearly the same as water. However, a
catch test (the LIQUID CALIBRATION routine) should be performed if there is reason to suspect
accuracy of the stamped value or if it is desired to more positively ensure accurate APR results.
The flow meter constant can differ for each liquid material, spray bar or boom, spreader vehicle, and flow
meter. Different flow meters are used for the pre-wet and anti-icing liquids.
D. Servo/Proportional Drive
The parameter called servo drive (SRVO DRV) asks the question "Does the liquid channel use a servocontrolled valve?" If a proportional valve is used, the answer is NO.
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E. Drive Frequency
The parameter DRV FREQ is the valve manufacturer's suggested drive frequency, as shown on the valve
specification sheet. The rated drive frequency for the DICKEY-john® servo valve is 100 Hz.
F. PWM Offset (Liquid)
The PWM OFFSET parameter appears on this screen regardless of whether a servo or proportional valve
is used. It defines the starting point of the valve operating range (i. e., the valve position at which the
flowmeter sensor first begins to generate feedback pulses). This parameter value is determined
automatically for the liquid channel during the (Fll-2 and Fll-3) LIQUID SYSTEM RESPONSE routines.
The value of this constant can be keyboard entered. Liquids dispensed from the anti-icing boom may
have a different PWM OFFSET constant than those from the pre-wet bar because of different plumbing
components.
G. PWM Saturation (Liquid)
The PWM SAT parameter appears on this screen only if a proportional valve is specified. It defines the
end point of the valve operating range (i. e., the valve position yielding the maximum pulse frequency
from the flowmeter). This parameter value is determined automatically for the liquid channel during the
(Fl 1-2 and Fl 1-3) LIQUID SYSTEM RESPONSE routines. The value of this constant can be keyboard
entered. Liquids dispensed from the anti-icing boom may have a different PWM SAT constant than
those from the pre-wet bar because of different plumbing components.
H. System Response
The following paragraphs on the SYSTEM RESPONSE calibration constants (SYS RSPNS, VALV
BOOST, PWM OFFSET, and PWM SAT) are for descriptive purposes only. That is, since these
parameters are automatically determined during the LIQUID SYSTEM RESPONSE calibration routines,
the values displayed for these parameters can be ignored during programming. This routine is always
performed, regardless of whether any other calibration routines require running.
The SYSTEM RESPONSE constant, SYS RSPNS, adjusts the response of the control system to the
hydraulic and mechanical systems of the liquid control channel on each particular spreader vehicle. The
value of this parameter is determined automatically for the liquid channel during the LIQUID PRE-WET
SYSTEM RESPONSE CALIBRATION routine for pre-wet liquids (Fll-2) and during the LIQUID
ANTIICING SYSTEM RESPONSE CALIBRATION routine for anti-icing liquids (Fll-3). These
constants can be fine-tuned later for optimum performance by keyboard entry as explained in Appendix
B.
I. Valve Boost
The valve boost constant, VALV BOOST, increases the amount of system gain initially applied to the
liquid control channel to cause it to reach final operating speed (i. e., the target APR) as quickly as
possible. The value of this parameter is determined automatically for the liquid channel during the (Fll-2
and Fll-3) LIQUID SYSTEM RESPONSE routines (at the same time the system response constant, SYS
RSPNS, is determined). This constant can be fine-tuned later for optimum performance by keyboard
entry as explained in Appendix B.
J. A Filter
The parameter AFILT is a feedback filter constant determined automatically during the SYSTEM
RESPONSE calibration routine. This parameter minimizes the effects of electrical noise and mechanical
vibrations on the feedback signal. The smaller the number the greater the degree of filtering. The value
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of this parameter can be changed manually as described under the heading "Fine-tuning System Response
Parameters" in Appendix B.
K. Tank Level
This sensor is used to monitor the liquid level for the pre-wet or anti-ice systems. The sensor is to be
connected to the main harness with the lead labeled TANK or an adapter harness that ties the tank level
signal to pin 13 of the 16-pin granular valve connector. The tank level sensor feature must be enabled in
the Control Point console before it will be active. It can be enabled for only one of the four liquid
materials being used. The tank level will only be displayed when enabled and the selected material that it
was enable under is active. (I.E. If liquid 1 is set up for prewet (prewet yes) with tank level enabled and
liquid 2 is anti ice (prewet no), the tank level will only be displayed when liquid 1 prewet is active. If the
Control Point has been configured for use with anti-ice/prewet switch input on boom 5 to automatically
switch between liquid 1 prewet and liquid 2 anti ice, the tank level will be displayed only when the
switch is in the prewet mode. If the switch is in anti-ice mode, the tank level will not be displayed. If the
tank level is desired for liquid 2, enable tank level under the liquid 2 configuration screen. Note: This
will disable the tank level on liquid 1.) When enabled, a bar graph and a digital readout representing the
tank level will be displayed. If granular is enabled, the spinner bar graph will share its portion of the
operate screen with the tank level bar graph. If the tank level is disabled, the spinner bar graph will be
displayed across the lower section of the operate screen.
L. Other Liquid Materials
If all liquid materials to be used are not yet programmed, press F5 to return to the (LIQUID)
CONFIGURATION screen (Figure 31) and select the next material to be programmed. It is
recommended all pre-wet liquids be programmed first to avoid confusion. (The flow meter constant
differs for those liquids using the anti-icing boom.) Enter any known flow meter constants (K-FACTOR)
for the remaining liquid materials and verify the servo drive and drive frequency parameter values
(SRVO DRV and DRV FREQ) are identical for all liquid materials.
If the K-FACTOR is not known, leave the values shown on the screen and the correct values will be
determined by running the LIQUID CALIBRATION routines later. Leave all SYSTEM RESPONSE
calibration constants as is since these will all be re-calibrated with the LIQUID SYSTEM RESPONSE
routines.
M. Boom Configuration
If the anti-icing boom is used, the boom sections are configured by pressing F5 to return to the (LIQUID)
CONFIGURATION screen, then 5 to obtain the BOOM CONFIGURATION screen. Next, press a key
numbered from I to 5 for the corresponding SECTION CONFIGURATION screen. The parameters for
this screen are explained as follows:
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1.
Section Enabled - To enable this boom section, enter Y (YES) after the parameter SECTN
ENBLED.
2.
12 Volts On - This parameter allows specifying the polarity of this boom section sense input
line to the Console. Entering Y (YES) after 12V ON means the presence of the vehicle battery
voltage on this input line indicates this boom section is turned on (activated).
3.
Number of Nozzles - Enter the number indicating the quantity of nozzles on this boom section
after NUM OF NZZLS.
4.
Nozzle Spacing - Enter the number of inches between nozzles after the parameter NZZLE
SPCNG.
16
5.
Boom Input - By entering Y (YES) after the parameter BOOM INPUT, what is normally the
boom section 5 sense input line can be used instead to sense the position setting of a Prewet/Anti-icing switch.
NOTE: SECTION 1 through SECTION 4 CONFIGURATION screens contain identical
parameters as SECTION 5 (explained above) with the exception of BOOM INPUT.
F6-CALIBRATION
See the Calibration section of the manual.
F7-2 GROUND SPEED CONFIGURATION
Press F7 to obtain the GROUND SPEED (MENU) screen. Then press 2 to select the GROUND SPEED
(CONFIGURATION) screen.
A. Max Speed
MAX SPEED is the maximum speed the operator can drive the vehicle, while the system is in the AUTO
mode, before a "MAX SPEED EXCEEDED" warning appears and an alarm is sounded. If a zero (0)
value is programmed for this parameter, this function (i. e., the monitoring and warning of excessive
speed) is disabled.
B. Manual On
If the ground speed sensor becomes damaged, it is still possible to temporarily operate the system,
without replacement of the ground speed sensor, by using an internally generated, simulated ground
speed signal. The supervisor activates this artificial ground speed signal by entering Y (YES) after the
parameter MANUAL ON displays on this screen. This signal is also useful for testing, troubleshooting,
or calibrating the vehicle while stationary.
C. Manual Driver
This parameter asks the question, "Should the driver be given the ability to engage the MANUAL
SPEED signal if the ground speed sensor fails?" Entering a Y (YES) adds text to the bottom of the
MATERIAL SELECT screen to allow this selection.
D. Manual Speed
MANUAL SPEED is used so that ground speed in miles per hour (MPH) can be simulated with an
artificial, internally generated signal. The operator (driver) must then maintain vehicle speed near this
MANUAL SPEED value to ensure materials are spread at the target APR.
E. 2 Axles
If the vehicle is equipped with a two-speed axle, enter YES for the 2 AXLES parameter.
F. Ground Speed Constant
The GROUND SPEED CONSTANT, shown on the screen simply as CONSTANT, is defined as the
number of pulses obtained from the ground speed sensor while the vehicle travels a distance of one (1)
mile. If known, this constant can be keyboard entered at this time. If entered now, be sure to also record
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this constant immediately in the CALIBRATION DATA RECORDS sheets at the rear of this manual. If
the GROUND SPEED CONSTANT is unknown, it will be automatically determined later, with the
GROUND SPEED CALIBRATION routine. Those vehicles equipped with a two-speed axle require two
ground speed constants, CONSTANT 1 and CONSTANT 2. CONSTANT 1 can be the GROUND
SPEED CONSTANT for either the Lo-speed axle or the Hi-speed axle, depending upon axle-shifter
polarity during GROUND SPEED CALIBRATION
F8 - SPINNER CONFIGURATION
The spinner configuration parameters identify the types of actuators and sensors used on the spinner
control channel and their performance specifications. To prepare for calibration of the system the
following spinner configuration parameters should be reviewed.
When a proportional valve is used for the spinner channel (i. e., SRVO DRV is NO) the parameters SYS
RSPNS, VALV BOOST, and AFILT do not appear on the (F8) SPINNER CONFIGURATION screen.
This is because no valve position-sensing feedback signal is available from a proportional valve as it is
for a servo valve.
Further, when a proportional valve is used for the spinner channel, the parameters PWM OFFSET and
PWM SAT must be manually set for proper operation. This must be deferred until after the
GRANULAR SYSTEM RESPONSE CALIBRATION has been run, under the heading Proportional
Valve Spinner Procedure.
A. Unload
This parameter asks the question, "Do you want the spinner to be activated during the UNLOAD
function?"
WARNING:
IF THIS PARAMETER IS ANSWERED ‘YES', EXTREME CARE MUST BE
EXERCISED BY THE OPERATOR TO ENSURE NO ONE IS AT THE REAR
OF
THE VEHICLE BEFORE BEGINNING TO 'UNLOAD', TO AVOID PERSONAL INJURY!
B. No Gnd Spd
This parameter asks the question, “Do you want the spinner to run when the truck is sitting still (the
ground speed signal is zero) at a stop sign?”
C. Drive Frequency
See description under heading F3 - GRANULAR CONFIGURATION.
D. Pulse Feedback
This is set active when a RPM sensor is installed on the spinner. When activated the screen will change
to include SPIN CON (Spinner Constant). The SPIN CON is the number of pulses that the Hall Effect
(or other feedback sensor) sends to the Control Point console per revolution of the spinner motor.
E. Blast Rate
The BLAST RATE if set to 0%, the SPREAD WIDTH ADJUST knob position determines the spinner
speed. Other values indicate the percentage of maximum spinner speed, regardless of knob setting.
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F. PWM Offset
See description under heading F3 - GRANULAR CONFIGURATION. This parameter relates to the
actuator valve position at which the spinner first begins to rotate (i. e., when the feedback sensor begins
to generate pulses).
G. PWM Saturation
See description under heading F3 - GRANULAR CONFIGURATION. This parameter relates to spinner
maximum rotational speed (i. e., the actuator valve position at which the sensor first exhibits the
maximum pulse frequency).
H. GSRS (Ground Speed Related Spinner)
This feature enables the Control Point to regulate the spinner speed related to ground speed. If GSRS is
YES the spinner configuration menu will be changed to include GSRS SLOPE and MAX GSRS. With
this configuration, the system will control the spinner related to ground speed and be running closed
loop. By controlling the spinner according to ground speed, the material can be dispersed at zero
velocity.
F9
ACCUMULATORS
Accumulators store current run and season run totals of mileage, material amount, and time spent
spreading materials in both the AUTO and BLAST modes. Separate totals are accumulated for each
material spread. Any or all current and season accumulators can be cleared (zeroed) anytime using the
keyboard but only the current accumulators (i. e., the CURRENT TOTALS screens) can be cleared using
the switch module if this function is enabled as described below.
To clear only the current totals accumulators for a given material, the supervisor performs the following
steps: Press F9 to obtain the ACCUMULATORS (MENU) screen, then I for the (GRANULAR)
ACCUMULATORS screen, then 1 for the SALT TOTALS screen. As indicated on this screen, pressing
the C key causes all CURRENT totals (located on the top half of this screen) to be cleared (for the
selected material only - in this example, SALT).
To clear both the season and current totals for a given material, the supervisor performs steps identical to
those in the previous paragraph except the S key (instead of the C key) is pressed in the last step.
To clear the accumulators for any of the remaining granular or liquid ice-control materials used on the
system, the supervisor simply selects the next material as before, starting by pressing F9 to obtain the
ACCUMULATORS (MENU) screen. The words ENABLED or DISABLED, shown after the material
names, have no significance in the resetting of accumulators.
To enable the operator to clear the CURRENT TOTALS screen only (typically done after completing the
current run), the supervisor performs the following steps: Press F9 to obtain the ACCUMULATORS
Notice the
screen, then press 3 to select the ENABLE/DISABLE CLEAR screen.
ENABLE/DISABLE CLEAR screen alternates, i. e., it asks the supervisor if a change from the existing
condition (enable or disable) is desired. (The operator procedures to accomplish clearing the CURRENT
TOTALS screen are detailed under the heading "Current Totals Screen" in the OPERATION chapter.
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NOTE: A similar screen entitled SYSTEM TOTALS, explained next, shows non-resettable totals of
time and mileage for the AUTO and BLAST modes of operation (for all materials
combined), as well as for vehicle usage.
F10 - SYSTEM INFORMATION
A. Alarm History
This screen records all errors encountered by the system. Included are the time and date of occurrence
and a brief description of the error. A total of 100 error events are recorded before the earliest occurring
errors begin to be dropped, one by one, as new errors are detected.
B. System Totals
This screen shows non-resettable totals of time and mileage for the AUTO and BLAST modes of
operation (for all materials combined) and for vehicle usage.
C. On/Off History
This screen shows the power history of the console. The screen provides up to the last 100 events of the
console powering up or powering down and the associated time and date.
D. Rate Change History
This screen shows the rate change history of the console. The screen provides up to the last 100 events
of the console application rate being changed for either the granular material or the liquid material.
E. Truck ID
This screen shows the current truck identification number. From this screen the Truck ID can be altered.
To change the Truck ID, by utilizing the keyboard, enter a new Truck ID and remove any unwanted
characters. When the entry reads as desired press enter to store the new setting.
F. Material Flow Alarm Label
This screen shows the material flow alarm label. From this screen the label can be altered. The material
flow alarm label can be changed to provide any alarm label to accompany the audible alarm when the
material flow lead reaches a low voltage state. To change the label, by utilizing the keyboard, enter a
new label and remove any unwanted characters. When the entry reads as desired press enter to store the
new setting.
F11 – SYSTEM RESPONSE CALIBRATION
Refer to the Calibration Section of the manual.
F12 - MISCELLANEOUS MENU
Certain parameters must be programmed to establish basic system performance. Press F12 to
obtain the MISCELLANEOUS MENU screen.
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A. Blast Setup
Press 1 for the BLAST SETUP screen. The BLAST TIMER value is the time period, in seconds, for
a timed blast cycle. If it is desired to initiate a timed blast with a momentary depression of the
BLAST button, enter any number between 1 and 99 seconds. If the operator presses the BLAST
button again before the period times out, the blast cycle terminates early. When the BLAST TIMER
value is zero (0), the blast cycle lasts only as long as the BLAST button is held depressed.
The BLAST SPEED value is an artificial vehicle speed, in MPH, used to compute the rate materials
are dispensed during blasting when the vehicle is at standstill or operating at a very low ground
speed. If the vehicle is moving slower than the programmed BLAST SPEED when the BLAST
button is depressed, material spreads at the higher, BLAST SPEED rate. If the vehicle is moving
faster than the programmed BLAST SPEED when BLAST is depressed, the blast spreading rate is
determined by the actual vehicle speed.
To enable blasting while the vehicle is stationary, a nonzero BLAST SPEED value must be
programmed. Pressing BLAST then causes material to be spread at a rate based on this BLAST
SPEED, even while the vehicle is stopped. This allows blasting an intersection while starting up the
truck from a standstill.
When BLAST SPEED is zero, blasting will not occur if BLAST is pressed while the vehicle is
stopped. In this situation, blasting begins (at a rate determined by the actual vehicle speed) only
when ground speed is sensed.
B. Time/Date
Press the F12 key to obtain the MISCELLANEOUS MENU screen, then press 2 to select the
PROGRAM TIME/DATE screen. Verify or correct the HOUR, MINUTES, AM/PM, MONTH,
DAY, and YEAR.
C. System Units
Press the F12 key to obtain the MISCELLANEOUS MENU screen, then press 3 to select the
SYSTEM UNITS screen. This screen allows changing from ENGLISH to METRIC units or vice
versa. Changing causes all parameter values on all screens to immediately convert to the equivalent
numerical values in the new system of units.
Only ENGLISH units are used in this manual to maximize readability. If METRIC units are chosen,
units substitutions are as follows: kilometers (KM) for miles, meters (M) for feet, centimeters (CM)
for inches, kilograms (KG) for pounds, and liters (L) for gallons.
D. Serial Port Configuration
Press the F12 key to obtain the MISCELLANEOUS MENU screen, then press 4 to select the RS232
CONFIGURATION screen. This screen is used to observe or modify the serial data format. Press 1
for BAUD RATE SELECT, 2 for DATA BIT SELECT , and 3 for PARITY SELECT screens. Use
the arrow keys to select values identical to the serial data format of the PC or other serial device to
be connected to the RS232 connector. (ENTER need not be pressed to store the values selected.)
E. Change Language
Press the F12 key to obtain the MISCELLANEOUS MENU screen, then press 5 to select the
CHANGE LANGUAGE screen. Changing causes all words and phrases on all screens to
immediately convert to the equivalent words and phrases in the newly selected language. The
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system displays English and one other language, usually French Canadian. On Control Point
versions 6.40 and later this feature is located under the SERVICE MENU.
F. Gate Height Sensor
When activated the screen will change to provide 5 user definable gate heights as well as an open
and closed setting to enter, which will aid in the gate height calibration. The calibration procedures
are as follows:
Calibration Steps
1. Notice that the cursor on the left side of the screen and position it to point at CLOSED.
2. Set the gate to the closed position.
3. Measure the height at the closed position and enter the gate height value for the CLOSED
setting.
4. Press C to capture the current gate height voltage at the CLOSED setting.
5. Move the cursor to SETTING 1.
6. Set the gate to the lowest operating gate height setting.
7. Measure the height at SETTING 1 and enter the gate height value for SETTING 1.
8. Press C to capture the current gate height voltage for SETTING 1.
9. Repeat steps 5-8 for the SETTINGS 2-5 starting with the next lowest setting.
10. Move the cursor on the calibration screen to the OPEN setting.
11. Set the gate to the OPEN height.
12. Measure the height at the FULL open position and enter the gate height for the OPEN
setting.
13. Press C to capture the current gate height voltage at the OPEN setting.
14. Press Esc when complete.
*When calibrating the gate height not all of the 7 positions need to be calibrated. The only required
calibration positions are CLOSED and OPEN. Settings 1-5 were added for better accuracy at the
operator’s desired gate heights. If a 2 point calibration is desired, enter the gate height value for the
CLOSED and OPEN positions and capture their respective voltages. Then individually select
settings 1-5 and press “D” to delete them. Press “ESC” when finished.
OPERATOR NOTES:
1. If the voltage from the sensor is outside the range between the CLOSED and OPEN position
values, the display will state GATE LOW or GATE HIGH. If GATE LOW is displayed, the signal
from the sensor is below the CLOSED voltage. If GATE HIGH is displayed, the signal from the
sensor is above the OPEN voltage. In either case, an alarm will be activated notifying the driver. The
alarm will tell the driver to check the gate height and set the gate to X.X (the gate height at which the
granular calibration was ran) for that granular channel.
2. If the gate height is enabled, all of the desired granular materials that have been enabled must be
calibrated. If materials that have been enable are not calibrated the Control Point will not control that
material based on gate height.
G. Road Temperature Sensor
To enable the Road Temperature Sensor enter the MISCELLANEOUS MENU, press 6 to enter the
second page, and then press 2 to enter the Road Temperature Sensor configuration. Once activated
the screen will change to provide the option to set three alarm temperatures. These are 3 user
definable temperatures alarms to alert the driver of changes in road temperatures. Through these
alarms the driver is aware that a change in application rate or material may be warranted. The
temperatures must be entered in descending order with ALARM TEMP 1 being the highest and
ALARM TEMP 3 being the lowest. TEMP HYST + This is the positive temperature change that has
to occur above the active alarm temperature to clear the alarm. (I.E. If alarm temp 1 is 20°F and the
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22
temp hyst + is 5°F, the alarm will activate when the temperature drops below 20°F and will clear
when the temperature reaches 25°F.)
From the Road Temperature Sensor screen calibration of the road temperature sensor is initiated.
Press C to start the RoadWatch Adapter automatic calibration procedure. (NOTE: The RoadWatch
temperature sensor must be disconnected and the RoadWatch Adapter must be connected for the
calibration to perform successfully. If the RoadWatch Adapter is disconnected when the calibration
is performed, an error screen will be displayed.) Calibration will last approximately 10-20 seconds.
The ROAD TEMPERATURE SENSOR menu will be displayed at the conclusion of the calibration.
* Road Watch is a registered trademark of Sprague∨ Controls Inc. Sprague Controls Inc. is a
registered trademark of Dana Corporation.
H. Air Temperature Sensor
To enable the Air Temperature Sensor enter the MISCELLANEOUS MENU, press 6 to enter the
second page, and then press 3 to enter the Air Temperature Sensor configuration. Once activated the
alarm configuration and calibration is the same as the Road Temperature Sensor.
I.
12V Boom Switched Output
This feature will provide a 12V signal for a valve driver to control a relay for an anti-ice boom shut
off. To configure the 12-volt switched output feature select Miscellaneous (F12), More (6), 12V
Boom Switched Output (4). Once on the 12V Boom Switched Output screen there will be an enabled
item.
Once the output has been enabled one of the following conditions must be met for the output to
function.
• All granular channels disabled.
• If Boom 5 is configured as an anti-ice/pre-wet switch, the switch must be in anti-ice mode.
• Anti-ice only mode.
Once one of the above conditions has been met and the liquid PWM is greater than 2%, the 12V
output will be activated. The 12V switched output is not a high current line, so to control a solenoid
valve you must have a power driver. The output will then activate the valve driver to control the
valve. To do this contact your distributor or DICKEY-john for the driver and the adapter harness.
NOTE: There will be no visual indication from the operator screen that this feature is enabled or
active.
J.
Down Pressure Sensor
The down pressure sensor is designed to allow the operator to view the relative pressure applied to
the belly scraper. The sensor uses the same input as the tank level sensor. Both the tank level and
the down pressure sensor cannot be configured or used at the same time. Connect the down
pressure sensor to the main harness lead labeled TANK or use an adapter harness (466492040S1) on
earlier versions of Control Point harnesses to connect the down pressure sensor signal to pin 13 of
the 16-pin granular valve connector. The down pressure sensor feature must be enabled in the
Control Point console before it will be active. It can be enabled through the miscellaneous menu and
can be viewed regardless of material selection. When enabled, a bar graph with a digital percentage
readout representing the down pressure will be displayed. By enabling the down pressure sensor the
tank level, if enable, is automatically disabled. If granular is enabled, the spinner bar graph will
share its portion of the Operate screen with the down pressure bar graph. The configuration and
calibration for the down pressure sensor is found under Miscellaneous (F12), More (6), Down
Pressure Sensor (5).
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CONFIGURATION
The initial down pressure screen has a YES or NO option for the sensor configuration. Press N for
NO and Y for YES. The default for the down pressure sensor is NO.
If NO, the following screen will appear:
If YES, the following screen will appear:
CALIBRATION
MIN PRESS
This value can be entered manually or automatically captured. This is the
minimum pressure that the sensor will see when belly scraper is up off the
pavement.
Manual Entry
Select the MIN PRESS text and enter the minimum pressure voltage from the
pressure sensors manufacturer’s specifications.
Automatic Entry Insure that the belly scraper is off the ground and the sensor is installed and
connected. Select the MIN PRESS text and press “C” to capture the sensor voltage.
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MAX PRESS
The value can be entered manually or captured. This is the maximum
pressure that the sensor will see with the scraper completely down.
Manual Entry
Select the MAX PRESS text and enter the max pressure voltage from the
pressure sensor manufacturer’s specifications.
Automatic Entry Insure that the scraper is down with the maximum pressure applied and the
sensor is installed and connected. Select the MAX PRESS text and press “C” to capture the sensor
voltage.
DOWN ALARM
This is a user definable percentage value of the maximum pressure.
When the down pressure exceeds the alarm limit an alarm will alert the
driver.
NOTE: The alarm will occur regardless of the master switch position.
K. Bed Height Alarm
This sensor will inform the operator when the bed has exceeded its recommended operating height.
The operator must inspect and maintain all mechanical linkage of the sensor on a regularly
scheduled interval to insure proper operation of the bed height alarm. Visual inspection of the
bed height must still 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 failure of the alarm to
indicate an unsafe operating height.
Connect the bed height sensor to the PRESSURE input on earlier version of Control Point main
harnesses and the GATE input on the current version main harnesses. Since the bed height sensor
uses the same input as the gate height sensor, both sensors cannot be configured at the same
time. If the gate height is configured and the bed height sensor is enabled, the gate height sensor
will automatically be disabled. The bed height sensor feature must be enabled in the Control Point
console before it will be active. It can be enabled through the miscellaneous menu and will function
regardless of material selection. The configuration and calibration for the bed height sensor is found
under Miscellaneous (F12), More (6), Bed Height Sensor (6).
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CONFIGURATION
The initial bed height screen has a YES or NO option for the sensor configuration. Press N for NO
and Y for YES. The default for the bed height sensor is NO.
If NO, the following screen will appear:
If YES, the following screen will appear:
CALIBRATION
BED DOWN
This value can be entered manually or automatically captured. This is
the voltage from the sensor when the bed is completely down.
Manual Entry
Select the BED DOWN text and enter the voltage from the sensor when the
dump bed is completely down.
Automatic Entry Insure that the Dump bed is completely down and the sensor is installed and
connected. Select the BED DOWN text and press “C” to capture the sensor voltage.
BED ALARM This value can be entered manually or automatically captured. This is
the voltage when the bed has exceeded it normal operating height.
Manual Entry
Select the BED ALARM text and enter the voltage when the bed exceeds the
normal operating height.
Automatic Entry Insure that the dump bed is at the near the maximum operating height and the
sensor is installed and connected. Select the BED DOWN text and press “C” to capture the sensor
voltage.
NOTE: The alarm will occur regardless of the master switch position.
L. Service Menu
This item is not intended for customer use. It is a service feature only, for incorporating future
product enhancements and to identify the software version currently installed.
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All calibration constants not entered during PROGRAMMING must be determined by performing the related
CALIBRATION routines found in the next chapter. Even if all possible calibration constants have been
entered for a given vehicle, the SYSTEM RESPONSE CALIBRATION routines must still be run on that
vehicle to properly prepare it for spreading materials.
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CALIBRATION
Calibration consists of performing all calibration routines necessary to allow the Control Point® system to
automatically calculate and store all system calibration constants. The calibration constants characterize the
performance of the granular, liquid, and spinner control channels, the hydraulic and mechanical systems, and
the vehicle ground speed sensor. Each granular and liquid material type used requires it's own separate
calibration. All calibration constants are stored in the systems non-volatile memory and displayed on the
appropriate screens. These constants must all be properly determined to ensure accurate system operation.
Calibration Routines
The routines used to calibrate the Control Point® system, in the recommended order of their execution, are the
GROUND SPEED CALIBRATION, the SYSTEM RESPONSE CALIBRATION, the GRANULAR
CALIBRATION, and the LIQUID CALIBRATION. If any constants normally determined by these
calibration routines were already known and entered at the time of programming, the related calibration
routines need not be performed.
Calibration Data Record
It is important to write down all calibration constants (for each granular and liquid material used, the hydraulic
and mechanical system response, and the ground speed sensor) and the other system parameters which are
listed on the CALIBRATION DATA RECORD. This ensures rapid recovery of operation in the event of
console damage or other loss. If a damaged Control Point® console requires replacement, all system
parameters recorded on the CALIBRATION DATA RECORD sheets can then be transferred directly to the
new console via keyboard entry. If additional CALIBRATION DATA RECORD sheets are required, make
copies and keep them with this manual.
Multiple Calibration Runs
To minimize the effects of operator measurement and other procedural errors possible during "catch test"
procedures, the GRANULAR CA-LIBRATION and LIQUID CALIBRATION routines should be repeated
several times (three times are recommended for each material) and the results averaged and keyboard entered.
Similarly, the GROUND SPEED CALIBRATION should be repeated and averaged. In all cases, the more
runs averaged, the less error likely. The SYSTEM RESPONSE CALIBRATIONS, on the other hand, need
not be repeated.
When performing multiple runs of a particular calibration routine to obtain an averaged result for a constant,
the supervisor observes and temporarily records the results of each run. Immediately after the averaged value
is keyboard entered onto the appropriate screen (storing it in system memory), this value is written on the
CALIBRATION DATA RECORD sheet.
F6-1 GRANULAR CALIBRATION
The GRANULAR CALIBRATION routine determines the spreader constant (SPR CON) for a given
granular material, vehicle, and gate height setting (for gates on V-box spreaders only). The spreader
constant is defined as the number of pulses generated by the application rate sensor per pound of granular
material discharged. This routine must be run separately for each granular material used.
The GRANULAR CALIBRATION routine (also referred to as a granular "catch test") causes the control
system to run the conveyor/auger mechanism, dispensing material while the vehicle is stationary. When
a sufficient amount of material has been discharged, the spreader should be stopped, the material should
11001-1281
28
be weighed and entered in the console utilizing the keyboard. The system then calculates, stores, and
displays the SPR CON. The procedural steps are as follows:
1.
Load the vehicle hopper with the desired material, loading enough to provide a uniform material
flow throughout the calibration procedure. Verify the gate height is adjusted to the proper setting.
2.
Press F6 on the keyboard to obtain the CALIBRATION MENU screen, then press 1 for the
GRANULAR CALIBRATION screen. Press the number corresponding to the granular material to
be calibrated. (The words ENABLED and DISABLED on this screen have no significance in the
calibration routine.) This gives the CALIBRATION screen for the selected material. If the material
DENSITY value displayed on this screen is incorrect, change it. This value directly affects the
accuracy of the accumulator totals.
3.
Position a suitable container or drop cloth to catch all the material as it is dispensed by the
conveyor/auger. The container must be large enough to obtain a good, representative sample. The
larger the sample to be weighed, the better the accuracy. Move the spinners out of the way, if
possible. Alternatively, if a vehicle scale is available, weigh the truck before dispensing material.
4.
Keeping the vehicle stationary, start the engine, engage the hydraulic system, and increase engine
speed to normal operating range (about 2000 RPM).
WARNING: THE NEXT STEP WILL CAUSE MATERIAL TO BE DISPENSED.
5.
Press "R" on the keyboard to run the conveyor/auger and start the calibration routine. Press the
granular channel " +/-" switch on the Switch Module, if required, to obtain a "normal" discharge
rate.
6.
When a sufficient amount of material has been dispensed, press “S” to stop. If a vehicle scale is
being used, reweigh the truck at this point. The resulting screen prompts for the material to weighed
and entered using the keyboard, then press "D" when done.
7.
The spreader constant (SPR CON) is now stored and displayed on this and on the GRANULAR
CONFIGURATION screen for this material.
8.
For maximum accuracy, it is recommended the entire above procedure be run performed at least
three times, temporarily writing down the resulting SPR CON each time. Average these and enter
the average as the final SPR CON. Then record this SPR CON for this material on the
CALIBRATION DATA RECORDS sheets at the rear of this manual.
9.
Repeat this procedure for each granular material used.
F6-2 LIQUID CALIBRATION
The LIQUID CALIBRATIONS determine the flowmeter constant (K-FACTOR) values for each of the
liquid materials used. The flowmeter constant is defined as the number of pulses generated by the
flowmeter per gallon of liquid dispensed. Separate calibrations are required for each liquid material
because of viscosity differences.
The LIQUID CALIBRATION routine (also referred to as a liquid "catch test") 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 material should be weighed and entered. The system then calculates,
stores, and displays the K-FACTOR. The procedural steps are as follows:
1.
11001-1281
Load the vehicle tank with the liquid material to be calibrated.
29
2.
Press F6 on the keyboard to obtain the CALIBRATION MENU screen, then press 2 LIQUID for the
FLOWMETER CALIBRATION screen. Press the number corresponding to the liquid material to be
calibrated. (The words ENABLED and DISABLED on this screen have no significance in the
calibration routine.) This gives the LIQUID CALIBRATION screen for the selected material. If the
material DENSITY value displayed on this screen is incorrect, change it. This value directly affects
the accuracy of the accumulator totals.
3.
Position a suitable container to catch all the material dispensed by the liquid pump. The container
must be large enough to obtain a good, representative sample. The larger the sample to be weighed,
the better the accuracy. (In the case of a pre-wet liquid material being calibrated, the pre-wet bar may
be removed from its mounting and placed with all its nozzles inside the catch container.
Alternatively, especially for anti-ice liquid materials, an appropriate hose may be temporarily
disconnected and placed inside the catch container.)
4.
In the case only where the liquid channel is propelled by the hydraulic system, start the engine,
keeping the vehicle stationary. Engage the hydraulic system, and increase engine speed to normal
operating range (about 2000 RPM).
WARNING: THE NEXT STEP WILL CAUSE LIQUID MATERIAL TO BE DISPENSED.
5.
Press "R" on the keyboard to begin the calibration routine. Press the liquid channel " + /- " switch on
the Switch Module, if required, to obtain a "normal" discharge rate. (The number in the middle of the
screen shows the counts accumulating from the APR sensor.)
6.
When a sufficient amount of liquid has been dispensed, press "S" to stop. The resulting screen
prompts for the material to be weighed and entered using the keyboard, then press "D" when done.
7.
The flow meter constant (K-FACTOR) is now stored and displayed on this screen and on the
LIQUID CONFIGURATION screen for this material.
8.
For maximum accuracy, it is recommended the entire above procedure be performed at least three
times, temporarily writing down the resulting K-FACTOR each time. Average these and enter the
average as the final K-FACTOR. Then record this K-FACTOR for this material on the
CALIBRATION DATA RECORDS sheets at the rear of this manual.
9.
Repeat this procedure for each liquid material used.
Fine-tuning the Granular Calibration
If small but consistent application rate errors are observed over a period of time, the spreader constant can be
modified to fine-tune application accuracy. See Appendix A, item 1 for the steps required to calculate the new
spreader constant, which is then keyboard entered on the (F3) GRANULAR CONFIGURATION screen.
Alternatively, the GRANULAR CALIBRATION routine can be repeated to correct this type of APR error.
Fine-tuning the Liquid Calibration
If, after using a flowmeter constant over a period of time, small but consistent application rate errors are
observed, its value can be manually changed to fine-tune application accuracy. See Appendix A, item 2 to
calculate the modified flowmeter constant, which is then keyboard entered on the (F5) LIQUID
CONFIGURATION screen. Alternatively, the LIQUID CALIBRATION calibration routine can be repeated
to correct this type of APR error.
Fine-tuning System Response Parameters
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30
If the APR oscillates more than +/-5% from the target APR, it may be possible to manually adjust the
parameters SYS RSPNS, VALV BOOST, and AFILT to improve system performance. Some oscillation of
the actual APR about the target APR is normal and will not adversely affect application. However, if
oscillation is excessive, a better tradeoff with response time may be possible by the manual adjustment
procedure described below.
Response time is defined as the time required for the system to reach a new target APR when the setting has
been changed while spreading materials (in AUTO). The response time is typically about two (2) seconds,
regardless of the amount of change in the target APR. Start-up time is defined as the time required to reach a
target APR value when starting from the Master Switch OFF condition. Vehicle ground speed is assumed to
be in normal operating range and is not involved in the definition of these terms.
The procedure for manually fine-tuning SYSTEM RESPONSE parameters for any of the four (granular, liquid
pre-wet, liquid anti-ice, and spinner) SYSTEM RESPONSE CALIBRATIONS is as follows:
1.
The SYSTEM RESPONSE CALIBRATION routine must be run first on the control channel to
automatically determine the initial parameter values. The system will not perform correctly without
this step.
2.
Examine the SYSTEM RESPONSE parameters shown on the appropriate CONFIGURATION screen
(Press F3 for granular, F5 for liquid, or F8 for spinner).
3.
If the system oscillates excessively, decrease SYS RSPNS by a factor of two (2) and evaluate system
performance. If it still oscillates too much, repeat this step. Do not decrease SYS RSPNS below the
point where response time becomes unacceptable.
4.
If the system still oscillates too much after adjusting SYS RSPNS, next try reducing AFILT by factors
of two (2) until the response becomes smoother.
5.
If instead the system does not oscillate but is too sluggish (response time significantly exceeds two
seconds), increase SYS RSPNS, realizing this will generally increase oscillation.
6.
Finally, the start-up time (defined above) can be decreased by increasing VALV BOOST. As this is
done, the system will increasingly overshoot the target APR. The optimum value of VALV BOOST
is a tradeoff between fast start-up time and acceptable overshoot. Change VALV BOOST initially in
whole number steps.
In general, it should not be necessary to change the parameter values outside the minimum and maximum
values. The SYSTEM RESPONSE parameters can be returned at any time to nearly their original values by
simply repeating the appropriate SYSTEM RESPONSE CALIBRATION routine.
F7-1 GROUND SPEED CALIBRATION
The GROUND SPEED CALIBRATION determines the ground speed constant (designated on the screen
simply as CONSTANT) for a given spreader vehicle and ground speed sensor. For those vehicles having
a two-speed axle, two ground speed constants are determined, CONSTANT 1 and CONSTANT 2. The
ground speed constant is defined as the number of pulses generated by the ground speed sensor while the
vehicle travels a distance of one (1) mile.
The GROUND SPEED CALIBRATION routine consists of driving a carefully measured course and
allowing the system to count the pulses from the ground speed sensor. The procedure follows:
11001-1281
31
1. Measure a one-mile (kilometer) course on level ground, plainly marking the start and finish points so
they will be plainly visible from the cab while driving past. Alternatively, two highway mileage
markers may be used.
2. Press F7 then 1 to obtain the GROUND SPEED screen, then 1 for the GROUND SPEED
CALIBRATION screen . This screen allows keyboard entry of the ground speed constant, if known.
3. Drive up to the start of the course at a minimum speed of 5MPH (8 Km/hr) and, when exactly even
with the start marker, press "S" on the keyboard (as prompted by the Figure 47 screen). The number
on the screen, initially zero (0), begins counting up, as the vehicle is moving.
4. Continue to drive the course at a reasonably constant speed, typical of normal operation. When even
with the finish marker, again press "S" on the keyboard to stop counting pulses.
5. The GROUND SPEED CONSTANT is automatically calculated, stored, and displayed. To ensure
best accuracy, it is recommended the above ground speed calibration procedure be performed three
times and the results averaged and keyboard entered.
6. Record the GROUND SPEED CONSTANT for future reference on the CALIBRATION DATA
RECORDS sheets at the rear of this manual. On those vehicles equipped with a 2-speed axle, the
ground
speed calibration procedure must be performed in both the Hi-speed and Lo-speed axle settings.
F11 SYSTEM RESPONSE CALIBRATIONS
The SYSTEM RESPONSE CALIBRATION routines determine the values of the System Response
constant, SYS RSPNS, and its related constants (VALV BOOST, PWM OFFSET, PWM SAT, and
AFILT) for the granular, liquid, and spinner control channels. These constants adjust the response of the
Control Point ®system to the hydraulic and mechanical systems of each of the three control channels on
the spreader vehicle.
Notice two different LIQUID SYSTEM RESPONSE CALIBRATION routines, one for the liquids used
on the pre-wet spray bar and one for those on the anti-icing boom, are used. The different flowmeters,
nozzles, and other "plumbing" components used by these two means of dispersing liquids cause the
related calibration constants to differ considerably.
The constants usually change only slightly each time a SYSTEM RESPONSE CALIBRATION routine is
run. Manual fine-tuning of these constants for optimum performance can be done later, if desired, as
explained under this chapter's heading "Fine-tuning System Response Parameters”. It is important to
write down all constants on the CALIBRATION DATA RECORD sheets each time one of these routines
is run or fine-tuning is performed, to establish a performance history.
When the granular SYSTEM RESPONSE CALIBRATION routine (F11-l) is run, an identical set of
values for SYS RSPNS, VALV BOOST, PWM OFFSET, PWM SAT, and AFILT are automatically
calculated, stored, and displayed on the GRANULAR CONFIGURATION screens for all (up to four)
granular materials. The LIQUID PRE-WET SYSTEM RESPONSE CALIBRATION (F11-2) establishes
a similar set of parameters for all pre-wet liquid materials. The LIQUID ANTI-ICE SYSTEM
RESPONSE CALIBRATION (Fll-3) does the same for all anti-ice materials used on the system. The
SPINNER SYSTEM RESPONSE CALIBRATION (Fll-4) determines the spinner channel parameters. It
also correlates the fully clockwise position of the WIDTH ADJUST knob with the 100% mark on the
SPREAD WIDTH bar display.
The following is an explanation of the GRANULAR SYSTEM RESPONSE CALIBRATION routine.
All the other SYSTEM RESPONSE CALIBRATIONS are very similar and, therefore, are not
specifically discussed or shown.
11001-1281
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1. Press F11 to obtain the SYSTEM RESPONSE CALIBRATION (MENU) screen, then press 1 for the
initial GRANULAR SYSTEM RESPONSE CALIBRATION screen.
WARNING: THE NEXT STEP WILL CAUSE MATERIAL TO BE DISPENSED.
2.
Press "R" on the keyboard to start the calibration routine and obtain the "CALIBRATING" screen .
When the calibration is complete, the final GRANULAR SYSTEM RESPONSE CALIBRATION
screen appears, prompting “press the "C" key to continue”.
3. An identical set of GRANULAR SYSTEM RESPONSE parameters is now stored and displayed on
the GRANULAR CONFIGURATION screen for each granular material used. Shows the SALT
CONFIGURATION screen with the GRANULAR SYSTEM RESPONSE parameters displayed. As
mentioned previously, it unnecessary to perform multiple runs and average the SYSTEM RESPONSE
CALIBRATION routines, as for the other calibration routines. This is because these routines are
completely automatic and independent of operator procedure.
4. Repeat this procedure for the remaining control channels.
Updating Calibrations
If a new material is added for which the spreader or flowmeter constant is not accurately known, the
GRANULAR or LIQUID CALIBRATION routine must be run. Also, if wear of the conveyor/auger
mechanism, actuator valves, flowmeter, nozzles, or other system components is suspected, a new catch
test (GRANULAR or LIQUID CALIBRATION) should be performed to reestablish APR accuracy.
If new or different tires are installed, the GROUND SPEED CALIBRATION should be repeated. 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).
Repair or replacement of any system components, including hydraulic hose and hydraulic fluid changes,
as well as normal wear make it necessary to periodically recalibrate the system. Even without known
changes, the SYSTEM RESPONSE CALIBRATIONS should be performed at minimum intervals of one
year. A good rule of thumb is to recalibrate all three control channels at the start of each spreader
season".
TROUBLESHOOTING
11001-1281
33
Since each component of the Control Point® system performs a specific function, the control system usually reacts
in a predictable manner when components fail. If all symptoms are known, it is relatively easy to isolate the failed
component. If any of the components are not operating properly, such as the hydraulic pump or hydraulic motors,
the spreader will not perform to its maximum capability and the console may incorrectly appear to be at fault.
Component
Connected To
Function
Console
12VDC vehicle battery
and all components of
control system.
Compares vehicle ground
speed to conveyor / auger
and liquid pump speeds and
controls the hydraulic valves
(or DC motor for liquid) for the
desired application rates.
Switch Module
Console
Provides operator controls for
system real-time functions.
Vehicle Ground
Speed Sensor
Vehicle mechanical or
electronic speedometer.
Indicates vehicle ground
speed to Console.
Sensors for
Application Rate
and Spinner Speed
Conveyor / auger and
spinner or related
hydraulic motor shafts,
plumbing after liquid
pump.
Indicate conveyor / auger speed,
spinner speed, and liquid flow
rate or pressure to Console.
Actuators for
Servo or Proportional
Valves and Liquid
Pump
Conveyor / auger and
spinner hydraulic
control valves and
liquid pump.
Regulate conveyor / auger speed,
spinner speed, and liquid flow
rate.
Harnesses
All components
Connect all components.
11001-1281
34
Common Spreader Problems (with properly Operating Control System)
Symptom
Probable Cause
Corrective Action
Conveyor/auger will not Hydraulic pump off.
run in either AUTO or
UNLOAD
Manual valve closed.
Convey/auger will not
reach maximum speed
Engage pump.
Open valve.
Hydraulic quick-connector
loose.
Reconnect.
Conveyor/auger jammed
Clear jam.
Relief valve operating at
low pressure.
Adjust or replace.
Loss of hydraulic oil.
Repair leak and refill oil.
Faulty hydraulic system.
Repair hydraulic system.
Conveyor/auger binding.
Eliminate binding.
Relief valve defective or
set lower than specified.
Adjust to proper pressure
or replace valve.
Material lumping and
jamming conveyor/auger.
Clear.
Engine RPM low because
using wrong gear or axle.
Shift to lower gear
and/or axle.
Inaccurate application
Material density changed
(APR error exceeds 1 0%) from original calibration.
Feed-gate setting changed.
Repeat Granular Calibration.
Set gate to position used
during Granular Calibration.
Inaccurate ground speed
Repeat Ground Speed
input because tire size or
Calibration.
axle ratio has been changed.
11001-1281
35
SYMPTOM 1: Console will not power on.
Problem Cause:
1. Blown fuse.
2. Poor battery connections.
3. Damaged power cable.
4. Defective Console.
Corrective Action:
1.
2.
3.
4.
Check fuse, located in positive battery lead. If blown, replace with blade-type, 15-amp fuse.
Check battery connections for correct polarity. Remove corrosion.
Visually inspect power cable from rear of Console to battery. If damaged, replace cable or repair as
described under the heading "Temporary Field Repair of Cables".
If no problem can be found with power connection or power cable, Console may be at fault. Contact
Dickey-john Technical Service. See last page for phone and fax numbers.
SYMPTOM 2: "MANUAL" message is displayed (flashing). Conveyor /auger runs in AUTO with vehicle
moving.
Problem Cause:
1.
2.
3.
APR sensor coupling to shaft slipping or disconnected.
APR sensor cable cut.
Defective APR sensor.
Corrective Action:
1.
2.
3.
Visually inspect the sensor to conveyor/auger shaft coupling. If damaged, repair or replace coupling.
Visually inspect the cabling between APR sensor and Console. If damaged, replace cable or repair as
described under the heading "Temporary Field Repair of Cables".
If no damage is found to the coupling or cabling, replace APR sensor. Contact Dickey-john Technical
Service. See last page for phone and fax numbers.
SYMPTOM 3: Control valve will not open in AUTO while vehicle is moving. Console displays zero ground
speed. Valve functions normally in UNLOAD.
Problem Cause:
1.
2.
Defective ground speed sensor or cable.
Defective Console.
Corrective Action:
1.
2.
11001-1281
Visually inspect cable between ground speed sensor and Console. If damaged, replace cable or repair
as described under the heading "Temporary Field Repair of Cables".
If no damage is found, replace suspected components, one at a time, with known good components to
isolate the faulty component. Contact Dickey-john Technical Service. See last page for phone and
fax numbers.
36
SYMPTOM 4: Actual APR, shown on Console, fluctuates more than 5% above and below the target APR while
vehicle speed remains steady.
Problem Cause:
1.
System Response constant, SYS RSPNS, is too large.
Corrective Action:
1.
See heading "Fine-tuning System Response Parameters".
SYMPTOM 5: Actual APR, shown on Console, is slow responding to ground speed changes or target APR
changes or it stabilizes at the wrong value.
Problem Cause:
1. System Response constant, SYS RSPNS, is too small.
Corrective Action:
1. See heading "Fine-tuning System Response Parameters
11001-1281
37
Temporary Field Repair of Cables
WARNING: This is only a temporary repair! Order and replace damaged cables and those components
which are molded to damaged cables as soon as possible to avoid further system damage due
to the creeping entry of chemicals.
Damaged cables can be repaired in the field. However, do not repair wiring inside the hydraulic control
valves, the ground speed sensor, or the APR sensors. Breaking the seals on these components voids the
warranty on the entire system. Do not attempt to repair cable connectors. The cable repair procedure is as
follows:
1.
Carefully cut away the cable cover and "packing material" (used to round out the cable) at the
damaged area.
2.
Strip about 1/2 inch of insulation from the damaged leads. Do not cut away any of the wire strands.
3.
Using alcohol, clean about two inches of the cable cover and the individual leads.
4.
Being careful to match wire colors, twist together the stripped ends of each damaged lead and solder.
CAUTION: Use only rosin-core (Not acid-core) solder.
5.
Tape over each repaired lead with vinyl electrical tape, being careful not to use too much tape.
6.
Add another layer of tape over all repaired wires, extending the full length of the repaired section.
7.
Make a paper trough, then apply silastic compound over the entire repaired section. Use enough
compound to fill in up to the ends of the cable cover.
8.
Allow the silastic compound to dry, then use a final layer of electrical tape to completely cover the
repaired area, extending about two inches onto the cable cover on each side.
9.
Secure the repaired cable with nylon cable ties to avoid future damage due to flexing and scraping.
11001-1281
38
SYSTEM RESPONSE
The Control Point® has three control channels, granular, liquid, and spinner. This document describes the
parameters that are used by each control channel, how changing them will impact performance, and how they are
initially determined by the System Response procedure.
Each control channel has an independent set of
parameters, meaning that parameter values established for one channel will not carry over to other channels. This
is the reason that the system response must be performed individually for each channel. The parameters and
tuning procedures are identical for the liquid and granular channels, so they will be examined first. When the
spinner channel is set up in the pulse feedback mode, it will also have a parameter set that is identical to the
granular and liquid channels. The special case of no pulse feedback on the spinner will be examined towards the
end of this document.
Control Loop Parameters
The control loop parameters, which can be viewed through the keyboard F12 (Misc) / 6 (Service Menu) / 4
(System Response) / 1-4 (Control Channel), are listed in the following table along with a description of their
purpose:
Sys Rspns*
Valv Boost*
Afilt*
PWM Offset*
PWM Sat*
L
M
Max Freq
Max Volt
Slope
Pot
Oobhl
Oobh
A number, typically between 5 and 15, that trades off speed of response against oscillation in the
response. Increasing this value makes the channel quicker responding but more oscillatory.
A number used to provide a kick to the control channel when it is first activated. It is used
primarily for servo valves to help them rotate more quickly through the dead area as they first
open up.
A number, which must be between 0 and 1, which indicates how much filtering is applied to the
application sensor. A value of 1 means that no filtering occurs and the raw sensor measurement
is used in the control channel (which is usually bad). When Afilt is close to 0, so much
averaging is going on in the filter the estimate of the sensor RPM changes very slowly, which
may make the control overshoot wildly and appear sluggish.
This is the amount of PWM that is required to let flow begin for proportional valves or let the
servovalve to open. If this value is too large, the channel will oscillate from off to on during low
speed operation. If it’s too small, the system becomes more sluggish than necessary.
This is the PWM value that gets the maximum output out of the control channel for PWM
control. This parameter is most useful when it is desired to limit the maximum spinner speed.
L is the lag time for the channel. It is the time it takes for the output to change once a change in
the PWM has occurred. This number generally will be < 0.25 sec
Is the channel time constant + lag, which is the time it takes for the output to achieve 63% of any
commanded change. This ordinarily should be less than 2 sec.
The channel app sensor frequency (or pressure sensor voltage) when the control is 100% on.
The maximum put reading measured on servo valves when the valve is fully open.
This number is no longer useful for troubleshooting. It takes on the value PWMSat-Offset
This number is value read from the servovalve potentiometer when the channel is off.
This is what is called the proportional gain (mislabeled as INTEGRAL on some error screens).
It behaves similarly to Sys Rspns in that as it increases the system responds more quickly but
becomes more oscillatory. The actual value is highly dependent on the vehicle configuration.
This is the integral gain (mislabeled as PROPORTIONAL on some error screens. It should be
the same as or slightly larger than Oobhl. As this value gets larger, the control channel will do a
better job of tracking the desired application rate. If this gain gets too large. Low frequency
oscillations will appear in the channel output.
*Only these marked values can be adjusted in the channel set up menus. All values in this table are
defined by the System Response procedure.
11001-1281
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System Response Procedure
The purpose of the system response procedure is to find starting values for all of the parameters described in the
last section for a particular control channel. First and foremost, the SRVO DRV yes/no option must be properly
selected in the channel setup menu before attempting a system response trial. If the correct valve type is not
selected, the results from the system response will be meaningless and the control will not operate correctly.
The system response goes through several steps. If the system response fails during any step, the control
parameters computed up to that point are displayed along with a label indicating what step the system response
failed in. The user is given the option to accept or reject these parameter values. The following paragraphs
describe each of the system response steps and discuss why a failure might occur during a particular step.
Open Full
The purpose of the Open Full step is to turn the channel on 100% and measure the application sensor output at the
maximum flow. This routine will fail if the maximum flow is < 5 Hz. When it fails, none of the control loop
parameters are changed. Anything that prevents the application feedback from reaching the control can cause
failure during this step. The channel output (movement or flow) should be observed if there are problems with
this step. If there isn’t any output, some likely causes are no hydraulic power, no drive signal to the valve, and for
liquid channels no liquid, air in system, or pump needs primed. If there is output, the problem is most likely with
the feedback sensor and its wiring.
Servo Check
This step stores the maximum frequency (and maximum pot voltages for servo valves). It is unlikely for the
system response to fail during this stage.
Close Full
The Close Full routine turns the control channel completely off and tests application sensor output to make sure
that the channel did in fact close. If the sensor feedback signal exceeds 0.95% of the maximum found in the Open
Full step, the AFILT parameter is decreased. This is done because the feedback signal may just be noise at this
point and increased filtering may eliminate it. AFILT will be adjusted downward, trying to eliminate noise until it
drops below 0.01. At that point, the assumption is that the feedback detected is genuine and due to valve
creepage. AFILT is then adjusted back to 0.125 and the criteria for testing for valve closure is adjusted so that the
creepage doesn’t prevent going to the next step. ). It is unlikely for the system response to fail during this stage.
Open Servo
This routine is called when the SRVO DRV parameter in the channel setup menu is set to yes. The purpose of this
step is to just crack the servo valve open by first rotating the valve through its dead zone. This prevents the time it
takes the valve to rotate through the dead zone from being confused with the channel lag time L (see Control
Parameters above), which is the time it takes for a change in the PWM input to be detected at the application
sensor.
If the valve cannot crack open, even after applying as much as 100% PWM, this step fails, and the option to save
parameters is presented. The only parameters that have newly computed values at this point are Max Freq, Max
Volt, Afilt, and Pot. The maximum frequency at this point should be consistent with the device RPM at 100% on,
or, in the case of a pressure transducer, Max Freq will contain the maximum sensor output voltage, which should
be consistent with the maximum liquid pressure. If AFLIT is < 0.125, it is an indication that the sensor input was
noisy and was in need of additional filtering. Max Volt and Pot should be consistent with the wiper voltages on
the servovalve potentiometer when it is full on and full off, respectively.
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Servo Delay
This is a servovalve step only. It is a pause after the valve was cracked open in the Open Servo step. This permits
any transients to pass so that the channel output is steady prior to the next step. It is unlikely for the system
response to fail during this step.
Open Record
This step measures the time it takes for the output to change once the control input (the lag L) as well as the time
it takes the system to achieve 63% of its maximum output (M). It will fail if the 63% level can’t be reached before
a timeout. It is important to make sure that MaxFreq (Hz, or Volts for pressure) is consistent with the maximum
output. Also, the channel output (movement or flow) should be observed to see if this channel is opening up
correctly. It should be possible to see the servo valve open quickly to its maximum position. Causes of failure are
similar to those described in the Open Full section.
If successfully completed, this section will define L, M, and redefine AFILT so that the filtering won’t remove
any signals that could actually be there based on the speed of the system (M-L).
Close Record
This step shuts off the control completely and tests to see that it actually did shut off. Failure means that the
system would not shut off. Control parameters that would have been defined by this point are L, M, Max Freq,
Max Volt, Afilt, and Pot. By this step, failure probably isn’t due to the types of things discussed under Open Full.
The most likely cause is that the Afilt value isn’t low enough to satisfactorily remove sensor noise, which may
often be a result of vibration. A close look at the sensor and its wiring is in order here.
Ystart
A servovalve only routine that performs the same function as Open Servo. It cracks open the valve prior to
computing the PWM Offset. A failure means that the valve would not crack open. If the system passed through
the Open Servo step, it should have no problem with this step. Things to check are the servovalve to make sure
that it is rotating, and the output (movement or flow), to make certain it is there. If those both look good, the
sensor signal is no longer getting to the Control Point so check the sensor and its wiring.
PWM Delay
This step delays processing 5 seconds to ensure that sensor outputs are stable before the search for the PWM
Offset begins.
PWM Offset
The PWM Offset is the minimum PWM signal required to make the channel output change. It is found by
applying PWM = 0 to the system and gradually increasing PWM until the output changes. If PWM > 75 and the
output still hasn’t changed this step fails, because both servovalves and proportional valves should generate output
at PWM values well below 75. The control parameters that would have been defined by this point are L, M, Max
Freq, Max Volt, Afilt, and Pot. Failure to find the offset means that the output could not be increased, so things to
check are the servovalve (if present) to make sure that it is rotating, and the output (movement or flow), to make
certain it is there. If those both look good, the sensor signal is no longer getting to the Control Point so check the
sensor and its wiring.
PWM Sat
The PWM Sat is defined as the PWM signal level beyond which the output will not increase. This routine is only
executed for proportional valves. For servovalves, PWM Sat = 100%. The procedure used is to turn the valve on
100% and gradually decrease the PWM until the output starts to decrease (which defines the saturation point).
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The channel output (movement of flow) should be seen to jump to 100% and then at some point decrease.
IMPORTANT NOTE: If while running a system response on a proportional valve granular channel and the
spinner is not set up for pulse feedback, the spinner saturation and offset will automatically be set to the same
values as those selected for the granular channel. It is unlikely for the system response to fail during this step.
Start Control
This step shuts off the control completely and tests to see that it actually did shut off. Prior to entering this step,
all of the remaining control parameters are given initial values. If this step fails, the parameters displayed have all
been defined. Failure is a result of the sensor measurement indicating there is still flow. Noisy sensors and
creeping valves are the most likely problem sources at this point.
Cstart
This is a servovalve only step that cracks open the valve prior to exercising the control for tuning purposes.
Failure results when the valve fails to crack open. See the Open Servo and Ystart steps for a discussion of
possible causes.
Cstart Hold
This step waits until disturbances caused by cracking the valve decay. It is unlikely for the system response to fail
during this step.
Control Hold
This is the actual control tuning step. It applies a constant input command and examines the sensor feedback. The
responsiveness of the sensor is traded off against the amount of oscillation and a value of SYS RSPNS is chosen
that is a compromise between the two. A total of three passes are required through this step prior to determining
the best SYS RSPNS value. After each pass, the system jumps back to the Start Control step so that the effects of
the last pass have time to adequately settle down before the next pass begins. After the third pass, a System
Response Complete screen appears. There is no possible cause for the system response to fail during this step.
The value for SYS RSPNS that results from this routine is limited to between 5 and 15. If it is at 5, the indication
is that manually decreasing it more may make the system less oscillatory. If it is at 15, increasing it further may
make the system more responsive.
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APPENDIX A
Fine Tuning Application
1.GRANULAR
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:
300
New SPR CON = 100 x 315 = 95.2
NOTE: Keyboard enter the new SPR CON on the appropriate (GRANULAR) CONFIGURATION
screen.
2. LIQUID
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:
10
New K-FACTOR = 1000 x 9.5 = 1053
Spreader Constant Calculation
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
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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 Control
Point" shaft sensor)
60 for PIN 10844-OOOX
900 for P/N 10837-OOXX
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APPENDIX B
Manual Valve Adjustment for Servo Valves
If the system contains a dual servo valve, which will not open in either AUTO or UNLOAD manual adjustment of
the valve position is possible to allow continued spreading. The procedure is as follows:
Step 1.
Clean all dirt and foreign matter from the valve actuator cover and clamp.
Step 2.
Remove the clamp, cover, and gasket.
Step 3.
Loosen the valve coupling clamp and rotate the lower part of the coupling (See Figure 70).
Rotating the lower coupling clockwise to the stop completely closes the valve; counter clockwise
opens it.
Step 4.
Adjust the valve position until the approximate conveyor speed is obtained for the desired vehicle
speed and target APR. Tighten the coupling clamp.
Step 5.
Set the spinner speed using the same procedure.
Step 6.
Reinstall the gasket and cover and secure with clamp.
NOTE:
This procedure may require some "trial-and-error" adjustment until the correct setting is obtained.
Eliminating Conveyor or Spinner Creep
If the system contains a dual servo valve, which "creeps" (moves slowly when it should be stationary), correct
as follows:
Step 1.
Park the vehicle and place the system in MANUAL SPEED operation.
Step 2.
Perform all steps indicated under the heading "MANUAL VALVE ADJUSTMENT" above except
change Step 4 to:
Rotate the lower coupling clockwise until the creeping stops. Tighten the coupling clamp.
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APPENDIX C
Part Breakdown
The following pages contain information regarding individual Control Point® component parts.
1 Decal, DICKEY-john
Logo (46649-0650)
4 Button, Black
(20738-0010)
3 On/Off Pushbutton
Switch (20738-0006)
2 Decal, Control
Point (46649-0660)
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2 1/4”-20 X 3/4”
Hex Bolts (3)
(20014-0005)
3 1/4”-20 X 1”
Hex Bolts (2)
(20014-0027)
4 Optional Console
Only Mounting Plate
(46649-0370)
5 Washer, Rubber
(2) (46639-0900)
1 1/4”-20 Hex
Nut (2)
(20040-0011)
10 Retaining Clip (Holds
Switch Module Keyboard
Connector) (46649-0350)
7 Knob, Screw
(20072-0022)
8 Combination
Mounting Plate
(46649-0580)
9 #6 X 1/2” Screws (3)
(21389-0017)
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1 Rocker Switch SPDT
(21265-0010)
2 Master Rocker Switch
(21265-0039)
9 Rocker Switch SPST
(21265-0011)
3 Decal, Master Switch
(46649-0680)
10 Decal, Width Adjust
(46649-0690)
4 Decal, Blast
(46649-0670)
5 Blast Push Button
(20738-0005)
6 Button, Red
(20738-0009)
11 CP Switch Module Cover
(46649-0300)
7 Decal, Warning
(46649-1300)
12 Potentiometer
(21159-0007)
13 Disc
(44501-0002)
14 CP Switch Module Base
(46649-0400)
15 Screw (4)
(21389-0054)
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APPENDIX D
Wiring Diagrams
The following pages contain information regarding Control Point® harness wiring diagrams.
Control Point Main Harness
(46649-0485S1)
and
Crew Cab Harness
(46649-0486S1)
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Ang Signal
Gate Height
+12V Ground Speed
Ground Radar
Ground Speed Signal (Square Wave)
Ground Speed Fq2 ( Sine Wave)
Boom 1
Boom 2
Boom 3
Boom 4
Boom 5
Ignition
VI/WH
DKBLU
DKGRN
BRN
WHT
RED
BLK
BRN
WHT
GRY
RED
15
41
23
31
45
18
11
5
1
2
7
Dig Signal
Dig Signal
Dig Signal
Dig Signal
Dig Signal
Dig Signal
Freq Signal
Spinner Fq
OR/BLK
Freq Signal
24
Flowmeter
Liquid Fq
WHT
37
WH/RED
LTGN/BLK
LTGN/BLK
+12V
Ground
+12V
Ground
Liquid open
Liquid closed
Aper 2
Dig Signal
Freq Signal
Ang Signal
Ang Signal
Ang Signal
21
14
42
27
WH/RED
GRY
BRN
WHT
12
6
9
Ground Bat
+12V Bat
Material Level
Granular Fq
Spinner open
Granular open
WHT/BLK
TAN
PNK
VIL
33
47
32
26
BLK
RED
Tank Level
GRY
28
39
38
Air Temp
Pavement Temp
PUR
LTBL/BK
35
22
ARS
+ 12V Switched Output
ORG
20
PLUG
A
B
C
D
E
F
C
B
A
4
5
6
8
14
15
16
3
2
1
GRN
BLK
RED
WHT/BLK
TAN
PNK
VLT
BLK
BLK
RED
GN/BLK
GN/BLK
WHT/RED
A
B
C
A
B
C
3
1
2
4
9
8
RED
BLK
GRN
RED
BLK
GRN
BLU
GRN
BRN
WHT
RED
BLK
AUX.
A
B
C
RED
BLK
GRN
A
B
C
D
E
F
D
C
B
A
PUR
LTBL/BK
BLK
RED
RED
BLK
BRN
WHT
GRY
PLUG
C
B
A
ORG
BLK
RED
POWER
GATE HEIGHT
SPINNER SENSOR
FLOW METER
LIQUID VALVE
VALVE
TANK LEVEL
TEMPERATURE
SW +12 V
Control Point Retro Harness
(46649-0487S1)
3
4
4
3
Control Point Main Harness
(46649-0480S1)
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Control Point Retro Harness
(46649-1210)
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For DICKEY-john Service Department
Call: 1-800-637-3302
Fax: 1-877-603-8075
Website: www.DICKEY-john.com
For DICKEY-john Sales Department
Call: 1-800-637-2952
Fax: 1-877-603-8075
Website: www.DICKEY-john.com
For Service Repair Ship To:
DICKEY-john National Repair Center
5200 DICKEY-john Road
Dock # 2
Auburn, IL 62615
V – 6.40
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