Table Of Contents

Transcript

TABLE OF CONTENTS Safety Notices ...................................................................................................... 1 Introduction .......................................................................................................... 3 Features............................................................................................................................. 3 Requirements..................................................................................................................... 3 Component Overview .......................................................................................... 5 Flex4 Terminal ................................................................................................................... 5 Terminal Buttons ............................................................................................................................... 6 Terminal Connections ....................................................................................................................... 6 Operator Remote Switch Module........................................................................................7 Switch Module Functions .................................................................................................................. 7 Rate Control Module .......................................................................................................... 8 Output Module ................................................................................................................. 10 Miscellaneous Components............................................................................................. 12 Keyboard......................................................................................................................................... Ground Speed Sensor .................................................................................................................... Road Temperature Adapter (optional) ............................................................................................ Feedback/Application Rate Sensor (optional)................................................................................. Gate Height Sensors (optional)....................................................................................................... Hydraulic Pressure Sensors (optional)............................................................................................ Flow Meters..................................................................................................................................... Valve Control Output....................................................................................................................... Harnesses ....................................................................................................................................... Hopper Level Sensor (optional) ...................................................................................................... GPS Receiver (optional) ................................................................................................................. Video Camera (optional) ................................................................................................................. 12 12 12 13 13 13 13 13 13 13 13 13 Installation .......................................................................................................... 15 Switch Module Mount....................................................................................................... 15 Ram Mount Bracket Installation ....................................................................................... 16 Remote Switch Module Bracket Kit.................................................................................. 18 System Harness Connections.......................................................................................... 19 Cab Harness ................................................................................................................................... Rate Control Module Harness......................................................................................................... RoadWatch Temperature Adapter and Flex4 Interface Cable ........................................................ Extension Harness .......................................................................................................................... Output Module Harness .................................................................................................................. Electric Motor Driver Harness ......................................................................................................... 21 21 23 23 24 24 Operate Screen .................................................................................................. 25 Control Channels ............................................................................................................................ Display Function Buttons ................................................................................................................ Spread Width Bar............................................................................................................................ Road/Air Temperature Sensors ...................................................................................................... Boom Sections ................................................................................................................................ Conveyor......................................................................................................................................... Alarms ............................................................................................................................................. Accessory Sensors/Alarms ............................................................................................................. Ground Speed/Time/Date ............................................................................................................... 25 26 26 26 26 26 26 26 26 Display Settings (Camera/Display/Alarms) ...................................................................... 27 Flex4 Control System 11001-1576-201103 i TABLE OF CONTENTS Operation ........................................................................................................... 29 Pre-Operating Checklist .................................................................................................. Spreading Material .......................................................................................................... Blast................................................................................................................................. Pause .............................................................................................................................. Material Selection ............................................................................................................ 29 29 30 31 32 Turn Off an Active Channel ............................................................................................................. 33 Unload Material ............................................................................................................... Manual Ground Speed Override...................................................................................... Automatic Manual Control Channel Override .................................................................. Driver Login ..................................................................................................................... Route Selection ............................................................................................................... Boom Section Control...................................................................................................... Anti-ice Feature ............................................................................................................... Accessory Sensors.......................................................................................................... 33 35 36 37 37 38 39 39 Output Module Accessories............................................................................................................. 39 Hydraulic Accessory Tool Operation ............................................................................... 41 Current and Season Run Totals ...................................................................................... 41 Flex4 Programming ........................................................................................... 43 Passcode Restrictions ..................................................................................................... 43 Using the Keyboard ......................................................................................................... 44 Keyboard Functions......................................................................................................... 44 Text Entries ..................................................................................................................................... 45 Label Entries.................................................................................................................................... 46 Number Entries................................................................................................................................ 47 System Programming ....................................................................................... 49 Operate Mode (F1) .......................................................................................................... 49 Granular Channel Setup (F2) .......................................................................................... 50 Granular Rate Setup........................................................................................................ 51 Material Label .................................................................................................................................. Units ................................................................................................................................................ Spreader Constant .......................................................................................................................... Calibration Gate Height ................................................................................................................... Application Rate Method ................................................................................................................. Blast Rate ........................................................................................................................................ 51 51 51 51 52 53 Granular Configuration (F2)............................................................................................. 54 Drive Frequency .............................................................................................................................. PWM Offset ..................................................................................................................................... PWM Saturation .............................................................................................................................. System Response ........................................................................................................................... Valve Boost ..................................................................................................................................... AFILT ............................................................................................................................................... Material ............................................................................................................................................ Sensor Constant.............................................................................................................................. Spreader Constant .......................................................................................................................... Calibration Gate Height ................................................................................................................... ii 55 55 55 55 55 55 55 55 55 56 Flex4 Control System 11001-1576-201103 TABLE OF CONTENTS System Programming continued.......................................................................57 Liquid Channel Setup (F3) ............................................................................................... 57 Liquid Rate Setup ............................................................................................................ 58 Material Label .................................................................................................................................. 58 Units ................................................................................................................................................ 58 Application Rate Method ................................................................................................................. 59 Target Rate ..................................................................................................................................... 59 Minimum/Maximum Rate ................................................................................................................ 60 Inc/Dec Step.................................................................................................................................... 60 Blast Rate........................................................................................................................................ 60 Boom Configuration ......................................................................................................... 61 Function .......................................................................................................................................... 61 Active Level..................................................................................................................................... 61 Spinner Configuration (F4)............................................................................................... 62 Spinner Units................................................................................................................................... Unload............................................................................................................................................. Drive Frequency.............................................................................................................................. No Ground Speed ........................................................................................................................... Blast Rate........................................................................................................................................ Pulse Feedback .............................................................................................................................. Spinner Constant ............................................................................................................................ PWM Offset..................................................................................................................................... PWM Saturation .............................................................................................................................. System Response 63 Valve Boost ..................................................................................................................................... AFILT .............................................................................................................................................. Ground Speed Related ................................................................................................................... GSRS Slope.................................................................................................................................... Maximum GSRS ............................................................................................................................. 62 62 62 62 63 63 63 63 63 63 63 63 63 64 Auxiliary Control Channel Configuration (F5) .................................................................. 64 Accessory Sensors (F9)................................................................................................... 65 Gate Height Sensor......................................................................................................................... Road Temperature Sensor.............................................................................................................. Air Temperature Sensor.................................................................................................................. Tank Level Sensor Configuration.................................................................................................... Down Pressure................................................................................................................................ Bed Height ...................................................................................................................................... Digital Accessories .......................................................................................................................... Joystick Labels................................................................................................................................ 66 67 69 70 71 72 73 76 System Setup (F10) ......................................................................................................... 77 Blast Setup....................................................................................................................... 77 Blast Timer ...................................................................................................................................... 78 Blast Speed..................................................................................................................................... 78 Date and Time ................................................................................................................. 78 Units and Language......................................................................................................... 79 Service ............................................................................................................................. 80 Software Version............................................................................................................................. 80 System Reset.................................................................................................................................. 81 Troubleshooting ............................................................................................................... 82 GPS Sensor .................................................................................................................................... 83 Output Module Setup (F11) ............................................................................................. 84 Front/Rear Conveyor....................................................................................................................... 84 Left/Right Conveyor ........................................................................................................................ 84 Gate Height Control ........................................................................................................................ 85 Data Logging (F12) .......................................................................................................... 86 Alarm History................................................................................................................................... 86 Truck ID........................................................................................................................................... 87 Flex4 Control System 11001-1576-201103 iii TABLE OF CONTENTS Driver Setup..................................................................................................................... 88 Driver ID Configuration .....................................................................................................................88 Configuration Setup ......................................................................................................................... 90 Route Configuration......................................................................................................................... 91 Operational Totals ........................................................................................................................... 92 Lifetime Totals ................................................................................................................................. 94 Calibrations........................................................................................................ 95 Material and Spinner System Response Calibrations (F6).............................................. 95 Recording Calibration Data ............................................................................................. 96 Maintaining Calibration Accuracy .................................................................................... 97 System Response Adjustments....................................................................................................... System Response Constant ............................................................................................................ Valve Boost ..................................................................................................................................... AFILT ............................................................................................................................................... 97 97 97 98 Granular Drop Test Calibration........................................................................................ 98 Drop Test Preparation ..................................................................................................................... 98 Performing a Granular Drop Test .................................................................................................... 98 Granular Calibration Adjustments.................................................................................................. 101 Liquid Drop Test Calibration (F6) .................................................................................. 101 Drop Test Preparation ................................................................................................................... 101 Performing a Liquid Drop Test....................................................................................................... 101 Liquid Calibration Adjustments ...................................................................................................... 103 Auxiliary System Response and Drop Test ................................................................... 104 Spinner System Response Calibration .......................................................................... 104 Ground Speed Configuration (F8) ................................................................................. 108 Ground Speed Source................................................................................................................... Maximum Control Speed ............................................................................................................... Manual Speed On.......................................................................................................................... Manual Speed Access ................................................................................................................... Maximum Manual Speed ............................................................................................................... Manual Speed ............................................................................................................................... Control Startup Speed ................................................................................................................... Control Shutoff Speed ................................................................................................................... Ground Speed Constant ................................................................................................................ 108 108 108 108 109 109 109 109 109 Ground Speed Calibration (F8) ..................................................................................... 110 Import/Export Data Files ................................................................................. 113 Passcode Enabled......................................................................................................... 113 Export Configuration and Log Data Files....................................................................... 113 Import Configuration Files ............................................................................................. 115 Diagnostics ...................................................................................................... 117 Perform a Diagnostics Check ........................................................................................ Terminal......................................................................................................................... Control Module .............................................................................................................. Output Module ............................................................................................................... 117 119 119 123 Troubleshooting .............................................................................................. 125 Appendix A Converting Constants ................................................................ 129 Fine Tuning Application ................................................................................................. 129 Calculating Spreader Constants .................................................................................... 130 Warranty ............................................................................................................ 131 iv Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL SAFETY NOTICES Safety notices are one of the primary ways to call attention to potential hazards. An absence of specific alerts does not mean that there are no safety risks involved. This Safety Alert Symbol identifies important safety messages in this manual. When you see this symbol, carefully read the message that follows. Be alert to the possibility of personal injury or death. Use of the word WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Use of the word CAUTION with the Safety Alert Symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Use of the word CAUTION without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in equipment damage. Flex4 Control System 11001-1576-201103 SAFETY NOTICES / 1 OPERATOR’S MANUAL Flex4 Control System 11001-1576-201103 SAFETY NOTICES / 2 OPERATOR’S MANUAL INTRODUCTION The DICKEY-john Flex4 system can simultaneously control both granular and liquid snow and ice removal materials. Separate channels for granular and liquid precisely controls and maintains the desired applications. The flow of material varies automatically in proportion to the changes in ground speed so the application rate remains uniform. When Automatic mode is enabled, spreading automatically starts when the truck begins to move and will automatically stop when the truck stops. The operator interface consists of a: • • Console Switch Module Desired material application rates are entered on the Setup screens by attaching a keyboard. Figure 1 Flex4 Console and Remote Operator’s Switch Module FEATURES • • • • • • 7 inch color display 4 channel closed-loop control of granular, liquid, auxiliary (liquid or granular), and spinner functions Summer mode feature for roadside spraying, burming, and operation of hydraulic tools Day/night mode Optional camera to view rear of truck to monitor material dispensing and to avoid potential accidents Optional vehicle and fleet data management packages REQUIREMENTS The Flex4 system requires the following components for operation: • • • • Flex4 Control System 11001-1576-201103 Flex4 terminal Operator’s remote switch module Working set master module Keyboard (programming only) INTRODUCTION / 3 OPERATOR’S MANUAL • • • • • • 4 / INTRODUCTION Application rate sensor on salt spreader and flow meter on prewet system Application rate ECU to drive hydraulic valve and electric pumps to regulate material application Valve control devices Harnesses to connect system devices Ground speed sensor (from speedometer) GPS receiver (if vehicle tracking and data transfer is required) Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL COMPONENT OVERVIEW Components included with the Flex4 system: • • • • • • • Flex4 terminal Flex4 terminal mounting bracket and hardware Rate control module Remote switch module Remote switch module mounting bracket and hardware Cab power harness Rate control module harness Optional components: • • • • • • • • NOTE: Contact DICKEY-john Technical Support to order optional components at 1-800-637-3302. 10’ CAN extension harness Output module and harness Solenoid driver Electric motor/pump driver Camera 4.3mm lens Flex4 camera adapter 20’ camera extension Feedback sensors FLEX4 TERMINAL The Flex4 terminal is a 7” color display that provides simultaneous viewing of: • • • • • • • Rates Spread width Vehicle speed Spread direction Road temperature Joystick selection Accessory input monitoring Figure 2 Flex4 Terminal Terminal Buttons 1-6 Terminal Buttons 7-12 Home button returns to Operate screen or adjusts Operate screen layout Flex4 Control System 11001-1576-201103 COMPONENT OVERVIEW / 5 OPERATOR’S MANUAL TERMINAL BUTTONS • • • Twelve buttons are located on the left and right side of the terminal that correspond with screen text to provide screen navigation and quick adjustment to system settings Home button returns to Operate screen from any screen Home button adjusts Operate screen layout TERMINAL CONNECTIONS 1. Video camera connection 2. Terminal harness connection 3. USB RS232 port for data download and keyboard connection. The USB port can be used for the following purposes: – Transmission of current operation information and logged data for export to external hardware. – Accepts a USB memory device for exporting logged spread data for transfer to a laptop computer. – Import of system firmware updates to display terminal and master control module from USB memory device. – Imports system configuration files to program each display terminal and master control module with system calibration values. 4. Rotary button for scrolling through display menu items Figure 3 Flex4 Terminal Side and Back View 4 3 1 6 / COMPONENT OVERVIEW 2 Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL OPERATOR REMOTE SWITCH MODULE The Operator’s Remote Switch Module consists of buttons that control material application rate and spread width knob to adjust spinner speed and regulate spreading of material. The module is backlit for visibility during night operation and is mounted next to the display, driver seat arm rest, or on side of the electronic joystick hydraulic controller. Figure 4 Operator Switch Module Spread Width Knob SWITCH MODULE FUNCTIONS AUTO ON/OFF The Auto On/Off button regulates the amount of material applied in relation to the ground speed and turns the application of product on or off. PAUSE Pause button stops applying material but continues to calculate the total miles driven. Auto mode must be active for the Pause feature to operate. BLAST The Blast button applies material at a pre-programmed dispersal rate in Auto mode and manual override with Auto Switch in ON or OFF position. RATE (-) The Rate (-) button decreases the amount of pre-programmed material with each button press in Auto mode and manual override. RATE (+) The Rate (+) button increases the amount of pre-programmed material with each button press in Auto mode and manual override. SPREAD WIDTH KNOB Spread Width Knob adjusts the spinner speed to regulate material spread width. The spread width percentage will display on the console. Pressing the spread width knob will also select a channel to adjust. Flex4 Control System 11001-1576-201103 COMPONENT OVERVIEW / 7 OPERATOR’S MANUAL RATE CONTROL MODULE The Rate Control Module houses the system’s primary interface device. All system parameters, constants, and memory are stored in the module and controls material application by interfacing with valves and feedback sensors. 1. Select an area on the vehicle chassis to mount the Rate Control Module that allows for easy hookup and access. 2. Use the enclosure as a template to mark the location of the mounting holes. 3. Drill four 9/32 inch diameter holes where marked. Figure 5 Rate Control Module 7.45” 7.0” 3.93” 6.80” IMPORTANT: Do not use the enclosure as a guide when drilling. Do not overtighten nuts as this may damage the mounting tabs of the enclosure. The module can be mounted in any of the following orientations: Figure 6 Acceptable Orientation PREFERRED ACCEPTABLE ACCEPTABLE Do not install the module in any orientation other than shown in (Figure 6). The connection wires must not be mounted upward as moisture can collect inside the unit and damage the circuits. 8 / COMPONENT OVERVIEW Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL 4. Mount with the label side of module facing out. Do not mount with the connector facing up (see Caution). Connect any additional adapter harnesses to the module harness. The Rate Control module harness can accept an extension harnesses or the output harness. The Rate Control harness controls and provides connection to the following inputs: – 1 granular control channel – 1 liquid control channel (prewet or anti-ice) – 1 auxiliary control channel (liquid or granular) – 1 spinner channel – 2 application rate sensors – 4 hydraulic valves (PWM) – 1 down pressure sensor – 1 control valve (Servo) – 2 flow meters – 1 gate height sensor – 1 ground speed sensor – 1 remote on/off – 2 digital sensors – 1 hopper level sensor – 1 tank level sensor – 2 6-pin Servo connectors – 1 road/air temperature sensor adapter (optional) 5. Install sensors, valves, etc. per the instructions included with the items. 6. Install PWM valve assembly and feedback sensor for each control loop and connect the devices to their respective inputs on the harness making certain to match PWM 1/Servo 1 with FB1, PWM2/Servo 2 with FB2, etc. 7. Secure any unused and excess cable lengths where necessary. Flex4 Control System 11001-1576-201103 COMPONENT OVERVIEW / 9 OPERATOR’S MANUAL OUTPUT MODULE The Output Module is an auxiliary to the Rate Control Module to drive additional accessories installed on the vehicle such as boom section shutoff valves, open and close V-Box gates, switching valves for front/rear conveyors, switching valves for left/right discharge cross conveyors, and accessory 12 volt switched output. 1. Select an area on the vehicle chassis to mount the module that allows for easy hookup and access. Extensions may be used to reach members installed on remote areas of the vehicle. 2. The module can be mounted in the same orientations as the rate control module as illustrated in (Figure 6). Figure 7 Output Module 0.630 4.63 4.00 5.24 2.36 .291 2 HOLES 4.68 1.37 Do not install the module in any orientation other than illustrated in (Figure 6). The connection wires must not be mounted upward as moisture can collect inside the unit and damage the circuits. Ensure that module connectors do not face upward. 3. Mount with the label side of the module facing out. 4. To bolt the member to a frame: – Use the enclosure as a template to mark the location of the mounting holes. – Drill two 9/32 inch diameter holes where marked. – Attach to frame using 1/4 x 20 bolts or other fastening devices as illustrated in Figure 8. Do not use the enclosure as a guide when drilling. Do not overtighten nuts as this may damage the mounting tabs on the enclosure. 10 / COMPONENT OVERVIEW Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL Figure 8 Securing Member with Bolts TRUCK FRAME OR BED SUPPORT 1/4 FLAT WASHER 1/4 x 20 BOLT 1/4 NUT 1/4 SPLIT LOCKWASHER TRUCK FRAME OR BED SUPPORT 1/4 FLAT WASHER 1/4 x 20 THREADED "U" BOLT OR OTHER FASTENING DEVICE 1/4 NUT 1/4 SPLIT LOCKWASHER 5. To tie strap the module to a frame: – Use one long tie strap to loop around the member body and through both mounting holes as illustrated in Figure 9. – If necessary, drill mounting holes following the procedure described above. – Securely tighten tie strap. – Install a second tie strap toward the label end of the enclosure for additional support. Flex4 Control System 11001-1576-201103 COMPONENT OVERVIEW / 11 OPERATOR’S MANUAL Figure 9 Securing Member with Tie Straps TRUCK FRAME OR BED SUPPORT 6. Connect a output module harness to the output module and connect the output module harness to the Power/CAN backbone, refer to (Figure 16). 7. Connect each module harness to its module inserting both connectors until the connector locking tabs engage. 8. Lay out the boom shutoff harness along the boom frame to each of the shutoff outputs. 9. Route wires in locations where they will not be damaged. 10. Secure the harness with tie straps. NOTE: The last module harness in the system must have a CAN terminator installed for proper system operation. IMPORTANT: Be sure the locking tabs engage when inserting the connectors. The connection is sealed only when the locking tabs have fully engaged. MISCELLANEOUS COMPONENTS KEYBOARD A keyboard is required to program and calibrate the system. The keyboard has been environmentally hardened for use in the ice control field. After programming and calibration, the keyboard is disconnected and stored. GROUND SPEED SENSOR The ground speed sensor generates vehicle speed information for the console. Sensor electrical pulses proportional to the vehicle ground speed are vital to system operation because true vehicle ground speed is necessary for accurate product application. The system can function with a variety of electronic and mechanical speedometer sensors, such as hall effect and reluctance sensors. ROAD TEMPERATURE ADAPTER (OPTIONAL) Temperature sensors allow for direct readout of road temperature and ambient air temperature. 12 / COMPONENT OVERVIEW Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL FEEDBACK/APPLICATION RATE SENSOR (OPTIONAL) Feedback sensors send product flow information to the console for accurate product application. Both granular and spinner channels require pulsed electrical sensors having an output proportional to the mechanism speed. The liquid channel accepts either electrical-pulsed sensors or analog sensors with outputs proportional to material flow (pulsed). A liquid prewetting system only accepts pulsed feedback while higher capactiy anti-icing systems accept either pulsed or analog. GATE HEIGHT SENSORS (OPTIONAL) Measures gate height setting in inches and automatically adjusts conveyor speed to compensate for gate height changes and maintain application rate. HYDRAULIC PRESSURE SENSORS (OPTIONAL) Hydraulic pressure sensors measure the amount of down pressure applied on the underbody scraper. FLOW METERS Flow meter measures the flow rate of material being applied. VALVE CONTROL OUTPUT Flex4 rate controllers control PWM hydraulic and Servo valve electric motors that regulate material flow for accurate control of product application rates. Granular and spinner channels regulate the hydraulic oil flow rate to a motor. Liquid channels use various different configurations such as servo ball valves and electric pumps. HARNESSES Harnesses are included that are required for communication between the console and components. Optional extension harnesses are available for the Rate Control Module harness and output module harness when mounted in areas where additional harnessing is required. Electric motor driver harness is also available. HOPPER LEVEL SENSOR (OPTIONAL) A hopper level sensor can be used to trigger an alarm when material falls below the sensor mounting level. GPS RECEIVER (OPTIONAL) A GPS receiver for vehicle tracking. VIDEO CAMERA (OPTIONAL) A video camera installed on the rear of truck allows viewing of material dispensing and aids in backing the vehicle. Flex4 Control System 11001-1576-201103 COMPONENT OVERVIEW / 13 OPERATOR’S MANUAL 14 / COMPONENT OVERVIEW Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL INSTALLATION The Switch Module can be mounted next to the terminal with provided hardware or to the armrest using an optional remote switch module mount bracket. The standard hardware kit includes the following components: • • Ram Mount Kit (attaches terminal to vehicle dash) Switch Module Mount (attaches switch module to terminal) Optional remote switch module mounting hardware can be ordered separate that mounts the switch module to the armrest. SWITCH MODULE MOUNT The switch module mounting bracket attaches the remote switch module to the terminal and includes the following components: • • • • Main switch module mounting bracket Bracket shroud 3 Hex nuts 4 washers SWITCH MODULE BRACKET ASSEMBLY Attach Shroud and Module to Bracket: 1. Align shroud to the bracket (4) stud bolts. 2. Secure shroud to bracket with (4) washers. 3. Align switch module so the connectors insert through the module bracket connector opening and the (3) switch module stud bolts insert through the bolt holes of the bracket assembly. 4. Secure switch module to the bracket using (3) hex nuts. Figure 10 Switch Module/Terminal Bracket Switch Module Stud bolts (3) Connector opening 3 2 4 Switch Module Bracket Flex4 Control System 11001-1576-201103 Bracket 1 Stud Bolts (4) Shroud Hex Nut (3) Washer (4) INSTALLATION / 15 OPERATOR’S MANUAL Attach Terminal to Switch Module Bracket: 1. Loosen wing bolt of the RAM mount bracket and remove ball mount attachment. 2. Align the (4) holes on the switch module bracket to the terminal. 3. Align RAM ball mount with switch module bracket holes. 4. Secure terminal to bracket using (4) lock washers and (4) metric screws (included with RAM mount bracket). 5. Re-attach ball mount to RAM mount bracket and tighten wing bolt to secure. Figure 11 Attach Terminal Remove ball mount attachment RAM Mount Bracket Loosen wing bolt RAM Ball Mount RAM MOUNT BRACKET INSTALLATION The RAM mount bracket secures the terminal to the vehicle dashboard or other surface suitable for operator viewing using a ram mount bracket. • • Ball mount at top and bottom of bracket allows for orientation in many different positions. Wing bolt in middle of bracket tightens and secures the terminal to the desired position. The terminal mounting kit includes the following: • • • • • • 16 / INSTALLATION 1 ram mount bracket 4 metric screws 4 SAE screws 4 hex nuts 4 washers #10 4 washers 1/4 Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL CAB TERMINAL BRACKET ASSEMBLY 1. Secure bracket to truck cab using 4 SAE screws (included). 2. Adjust terminal for ideal viewing by loosening/tightening the wing nut. Figure 12 Cab Terminal Mount Secure Ram mount bracket (4) SAE Screws Position terminal so that operator view is not obstructed and does not interfere with tractor operation. Flex4 Control System 11001-1576-201103 INSTALLATION / 17 OPERATOR’S MANUAL REMOTE SWITCH MODULE BRACKET KIT The optional Remote Switch Module bracket kit allows mounting the switch module to the armrest. This kit is available separately and can be ordered by contacting the DICKEY-john Technical Support Group at 1-800-637-3302. To install Bracket: 1. Place the rubber washer between the bracket base opening and the side bracket opening aligning with the 1/4-20 nut. 2. Place bolt through the side bracket and washer to secure to the bracket base. 3. Remove (2) screws from the flat surface of the armrest. 4. Align bracket base to the armrest holes and secure to the armrest with the (2) screws. 5. Attach switch module to bracket as illustrated in (Figure 10). Figure 13 Remote Switch Module Bracket Installation Rubber Washer Secure bolt Remove armrest screws, insert bracket, re-attach screws 18 / INSTALLATION Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL SYSTEM HARNESS CONNECTIONS The Flex4 control system connects to the truck cab harness and is powered on and off when the ignition switch is powered on and off. System harnessing connections include: • • • • • • Cab harness Rate control module harness Output module harness Optional extension harness Optional electric motor/pump driver harness Optional RoadWatch Adapter and Flex4 interface cable Figure 14 System Architecture with Electric Motor / Pump Driver and Optional Output Module Harness Optional Video Camera Flex4 Terminal 467980507 GPS Receiver (optional) CAN Terminator Wireless Module (future release) Output module 466492101 Switch Module 466495210 Extension Harness 466495060 Cab Harness 466495051 Rate Control Module 467985410S1 Rate Control Module Harness 466495071 Application Rate Hydraulic Valve Output Module Harness 466495081 Gate Height Sensor Down Pressure Boom Shutoff Valve Flex4 Interface Cable 466495072 Battery Temperature Sensor 11001-1576-201103 connects to Rate Control Module harness Flow Meter Control Valve Flex4 Control System Electric Motor/ Pump Driver 466495430 Road Watch Adapter INSTALLATION / 19 OPERATOR’S MANUAL Figure 15 System Architecture with Electric Motor/Pump Driver Harness Optional Video Camera Flex4 Terminal 467980507 GPS Receiver (optional) CAN Terminator Wireless Module (future release) Rate Control Module 467985410S1 Switch Module 466495210 Rate Control Module Harness 466495071 Extension Harness 466495060 Cab Harness 466495051 Connects to Rate Control Electric Motor/ Module Harness Pump Driver 466495430 Application Rate Hydraulic Valve Control Valve Flow Meter Flex4 Interface Cable 466495072 Gate Height Sensor Temperature Sensor Road Watch Adapter Down Pressure Battery 20 / INSTALLATION Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL CAB HARNESS NOTE: The ignition lead must be connected to switched +12VDC for the system to power up and down properly. 1. Connect the power leads directly to the battery. 2. Connect the ignition wire to a switched +12VDC. 3. Connect the chassis ground lead to a bare point of the cab frame that offers a good chassis ground connection. 4. Connect the CAN terminator, wireles module, switch module, RoadWatch, and GPS, to their respective connectors on the cab harness. Figure 16 Cab Harness Wireless Module (future Switch release) Module To Extension Harness Ignition or Rate Control Module Harness GPS Receiver Battery To Terminal CAN Terminator RATE CONTROL MODULE HARNESS 1. Connect the Rate Control Module harness to the mating connector of the cab harness (use an extension harness if additional length is needed). 2. Secure harness as needed. 3. Connect the module harness to the mating connectors of the CAN/ power backbone, if used. The Rate Control Module uses a 30 and 18-way connector with a jackscrew to secure the connector to the module. The output module uses a pair of 12-pin connectors. 4. Secure module harness as needed. Flex4 Control System 11001-1576-201103 INSTALLATION / 21 OPERATOR’S MANUAL Figure 17 Rate Control Module Harness Rate Control Module Cab or Extension Harness PWM Ch 4 Spinner PWM Ch 3 Granular PWM Ch 2 Auxiliary PWM Ch 1 Liquid CH4 Spinner Feedback CH1 Liquid Feedback CH2 Auxiliary Feedback CH3 Granular Feedback Ground Speed Terminator Electric Pump Driver Harness, Extension Harness, or Output Module Harness Digital 1 Sensor Digital 2 Sensor Hopper Level Sensor Remote Blast Ch2 Pressure/Bed Height (Analog 1) Down Pressure Sensor (Analog 4) Gate Height Sensor (Analog 3) Remote On/Off Flex4 Interface cable attaches to any of the analog 1-4 connectors. RoadWatch Temperature Sensor Adapter connects to the Flex4 Interface cable. Joystick Scraper Servo 1 Liquid Tank Level Sensor (Analog 2) Boom Section Servo 2 Auxiliary 22 / INSTALLATION Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL ROADWATCH TEMPERATURE ADAPTER AND FLEX4 INTERFACE CABLE The Flex4 Interface cable connects to any of the Rate Control Module Harness analog 1-4 connectors. The RoadWatch Temperature Adapter connects to the Flex4 Interface cable. The analog position must then be identified at the (F9) Accessory Sensor screen to identify what function is connected to the analog 1, 2, 3, or 4 connector. Figure 18 RoadWatch Temperature Adapter and Flex4 Interface Cable Connects to Rate Control Module Harness via Analog 1, 2, 3, or 4 connectors Flex4 Interface Cable Temperature Sensor Road Watch Adapter EXTENSION HARNESS Extension harness (10 ft) is optional and used when extra length is required to connect with the Rate Control Module harness and the Output Module harness. Figure 19 Extension Harness Flex4 Control System 11001-1576-201103 INSTALLATION / 23 OPERATOR’S MANUAL OUTPUT MODULE HARNESS Optional output harness controls boom section shutoff. 1. Connect the output harness to the mating connector of the Rate Control Module harness. 2. Use extension harness, if required. 3. Connect output module and boom shutoff modules to the mating connectors of the CAN/Power backbone. 4. Connect electric motor/pump driver harness, if used. Figure 20 Output Module Harness Output Module Electric Motor Pump Driver Harness Rate Control Module Harness or Extension Harness Output 1 Output 2 Boom Shutoff Valves Output 3 Output 4 Output 5 Output 6 Reverse Auger Conveyor Left Conveyor Right +12V Switch Out Gate Height ELECTRIC MOTOR DRIVER HARNESS Drives electric pumps or motors that draw high current (greater than 2 amps). Figure 21 Electric Motor Driver Harness To electric pump Rate Control Module Harness, Extension Harness, O d l 24 / INSTALLATION To PWM channel (liquid or auxiliary) Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL OPERATE SCREEN The Operate screen has five main structured areas to display button selections and operation functions that include: 1. Control channel application rate windows 2. Display function buttons on left and right side of display 3. Main operator window displaying alarms, temperature readings, spread width status bar, and optional video 4. Accessory/alarm status windows 5. Ground speed, time, and date information NOTE: Large font on the Operate screen indicates the control is active. Small font indicates the control is not active. Figure 22 Operate Screen Layout 1 2 2 3 4 5 (1) CONTROL CHANNELS Four control channels monitor granular and liquid applications and also controls spinner speed. Control channel windows display target application rates (APR) when the vehicle is stationary and the actual application rate when spreading material for granular and liquid materials. – Application of granular material (pounds/kilogram) per mile (km) or area based (pounds per sq ft/grams per sq/meter) (lbs/acre) – Application of liquid material gallon (liters) per ton based on the granular applications rate or gallons (liters) per mile (km) and gallons (liters) per sq yard (meter) (gal/acre) An auxiliary channel window allows selection of another granular or liquid channel with the same units available as channel one and two. Target rates of product control channels can be changed by pressing the respective Rate Increase/Decrease button on the switch module. An audible beep indicates a rate adjustment change. Flex4 Control System 11001-1576-201103 OPERATE SCREEN / 25 OPERATOR’S MANUAL Channels are turned on and off by pressing the respective CH ON or CH OFF function buttons. The channel window reads “OFF” when the channel is selected to be off and returns to the rate when turned on again. Channel must be selected using spread width knob. (2) DISPLAY FUNCTION BUTTONS Twelve buttons are located on the left and right side of the terminal that correspond with screen text to provide screen navigation and quick adjustment to system settings. NOTE: Interchange Spread Width Bar window with the Temperature Sensor window by pressing the terminal Home button. (3) SPREAD WIDTH BAR Spread width bar indicates spinner operation and spread width in percent. Value is adjusted using the spread width knob on the switch module. Rotating the spread width knob on the switch module changes the rotational speed of the spinner and indicates the percentage on the spread width bar display. The bar is at the 100% position when the knob is clockwise corresponding to maximum spinner speed. Pressing the spinner left and right arrows positioned on the sides of the spread width bar indicates the selected spinner to be changed. Both can be adjusted simultaneously. (3) ROAD/AIR TEMPERATURE SENSORS When enabled, the current road/air temperature displays on the Operate screen with current readings and triggers an audible alarm when outside of defined parameters. (3) BOOM SECTIONS Boom nozzle graphics appear on screen, when enabled, to indicate boom section on/off status. (3) CONVEYOR When enabled, a left/right conveyor symbol and a front/rear conveyor symbol provides current position and can be changed by pressing the respective buttons. (3) ALARMS Alarm text appears in this window when user-defined parameters are outside of limits set. (4) ACCESSORY SENSORS/ALARMS • • Digital and analog accessory sensors enabled will display sensor status in the lower display window. Accessory alarms will display in this area with a one beep audible alarm. The sensor status remains in red until issue is resolved. (5) GROUND SPEED/TIME/DATE • 26 / OPERATE SCREEN Ground speed is independent of product application and displays actual ground speed in the lower display window. A manual ground speed setting will also appear in this location, when enabled. Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL • Current time and date displays below the ground speed window. DISPLAY SETTINGS (CAMERA/DISPLAY/ALARMS) Display settings adjust the characteristics of appearance and volume of the terminal: • • • Camera settings (appearance of the camera window display on the terminal) Display brightness (lightness/darkness of screen) Alarm volume (high/low adjustment of audible alarm when error occurs) To change a Display Setting: 1. At the Operate screen, press the Display Settings button to display the Display Settings screen. Refer to . 2. To modify a display setting, press the Camera, Display Brightness, or Alarm Volume button. 3. Press the Increase button or Decrease button to adjust the bar graph. Each time the button is pressed the setting changes and is visible on the screen with a percent adjustment. NOTE: Pressing the Back button returns to previous menu. Camera settings, display brightness, and alarm volume values are adjusted in bar graph form. – The Camera Settings bar graph indicates the appearance of the camera window on the display allowing adjustment to brightness, contrast, saturation, hue, and rotation. – The Display Brightness bar graph indicates the brightness level of the display. A full bar graph indicates the most brightness. The brightness changes each time the Increase/Decrease buttons are pressed. – The Alarm Volume bar graph indicates the volume level for the audible alarm. An empty bar graph indicates the lowest volume; a full bar graph indicates the highest volume. The volume level will sound each time the increase/decrease arrows are pressed. Flex4 Control System 11001-1576-201103 OPERATE SCREEN / 27 OPERATOR’S MANUAL Figure 23 Display Settings Screen ABC Adjustment Buttons A Camera Window 1 6 2 7 Day/Night 3 Mode Adjustment 8 50% 9 A B 4 C 5 B 10 C 11 Current Display Settings DAY AND NIGHT MODE Day and Night mode adjusts the terminal screen colors for better visiblity to sunlight or while operating at night. The default screen setting is night mode. To change Day/Night Mode: 1. Press the Day Mode On button (item 3) to change to the Day Mode setting. Press again to return to the night mode setting. Figure 24 Day and Night Mode Screens Day Mode 28 / OPERATE SCREEN Night Mode Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL OPERATION The Flex4 system powers on when the ignition switch is turned on. A DICKEY-john startup screen and Flex4 screen displays for up to 45 seconds before the Operate screen appears and the system is operational. The console automatically closes all system actuators and performs self tests including system configuration and application data during startup. If an error occurs at power up or during operation, an error message displays with recovery information. IMPORTANT: The system should be programmed and calibrated before spreading material. Figure 25 Powerup Screens PRE-OPERATING CHECKLIST The following procedures must be performed for effective operation: • • • NOTE: Channel and spread width windows can be interchanged on the Operate screen by pressing the Home button located on the lower right side of the terminal. Flex4 Control System 11001-1576-201103 Perform System Response procedure for all granular, liquid, and auxiliary channels Calibration of ground speed sensor Material application rates entered for each product to be applied SPREADING MATERIAL To begin Spreading Material: 1. Press the Auto On/Off button to engage Automatic mode. AUTO appears on the display when the system is stationary. 2. As the vehicle starts moving, AUTO is replaced with the material application rate relative to the ground speed. When the vehicle stops, material application will stop. OPERATION / 29 OPERATOR’S MANUAL To increase/decrease a rate: 1. Select the channel/material to change by pushing in the Spread Width knob on the switch module The selected channel will be highlighted in yellow. 2. With the selected channel highlighted, press either the Rate (-) or Rate (+) until the desired rate displays. NOTE: System setup is only accessible when the system is stationary with no ground speed. Figure 26 Operate Screen Auto enabled with 0 ground speed Application of material relative to ground speed NOTE: Application rate appears in small font when the control is not active. Rate appears in a larger font when the control is active. BLAST The Blast function is operable for both stationary and moving vehicle conditions to increase the amount of material spread by a predefined rate. Blast can be used in Auto mode, manual control channel override, and manual ground speed. To activate Blast: 1. Press the Blast button. An alarm sounds indicating Blast is activated and Blast will appear on the display. A Blast rate will automatically shut off if a time interval has been defined at the Blast Setup screen. If a predefined time interval has not been set, Blast is turned off manually by pressing the Blast button. 30 / OPERATION Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL Figure 27 Blast Feature Enabled BLAST BLAST PAUSE The Pause feature stops applying material while operating in Auto mode but continues to calculate miles driven. Pause can be used in Auto mode, manual control channel override, and manual ground speed. To activate Pause: 1. To enable, press the Pause button. An alarm sounds indicating Pause is activated and Pause will appear on the display. 2. To disable, press the Pause button again. An alarm sounds indicating Pause is disabled and will disappear on the display. Figure 28 Pause Feature Enabled Flex4 Control System 11001-1576-201103 OPERATION / 31 OPERATOR’S MANUAL MATERIAL SELECTION One granular, one liquid, and one auxiliary material can display simultaneously on the console display. To Change a Material: 1. With the vehicle stopped and ground speed at 0, press the Material Select button. 2. At the Material Selection screen, press either the Granular or the Liquid button. 3. Press the Select Arrow button to choose the desired material. Selected material will display in yellow. 4. When selected, press the Back button to return to the Operate screen. Figure 29 Material Selection GRANULAR LIQUID LIQUID CALCIUM SALT BRINE MATRL 7 AUX 32 / OPERATION MATRL 8 Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL TURN OFF AN ACTIVE CHANNEL A channel can be turned off while in Auto mode. 1. Push in the spreader width knob on the switch module to highlight the desired channel/material. To select the liquid channel, an additional press is required. 2. Press the CH OFF button. If a granular channel is turned off, any active material spreading in gallons/ton will also turn off simultaneously. A liquid channel can be independently turned off and the granular channel will stay active. 3. Press the CH ON button to re-activate the channel. Figure 30 Turning a Channel Off Liquid channel UNLOAD MATERIAL The Unload feature quickly removes remaining material from the vehicle. Vehicle must be stationary for operation to begin. To Unload Material: 1. Position vehicle to appropriate location with ground speed at 0. 2. At the Operate screen, press the Unload button. 3. At the Material Select screen, choose materials by pressing the corresponding button. Selected materials for removal will display at center of screen, i.e. “Salt Selected”. 4. Press the Start button to begin unload. 5. Press the Stop button when unload is complete. Flex4 Control System 11001-1576-201103 OPERATION / 33 OPERATOR’S MANUAL Figure 31 Unloading a Material START X X STOP Ensure the area is clear prior to unloading to avoid possible injury. 34 / OPERATION Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL MANUAL GROUND SPEED OVERRIDE Manual ground speed override is a manual override feature used when the ground speed sensor has failed. A manual speed can be entered in setup mode forcing the system to operate in manual speed mode and to spread material at the specified rate. To operate in Manual Override: 1. At the Operate screen, press the Material Select button. 2. At the Material Select screen, press the Manual Speed button. Continue pressing the Manual Speed button until Enable Manual Speed is highlighted. 3. Press the Select Arrow buttons to increase/decrease manual speed. Figure 32 Manual Override O.O O.O Increase/ decrease manual speed 4. Press the Back button to return to the Operate screen. Manual Speed is now enabled and displays on the Operate screen. When operating in manual mode, the system is turned on and off using the Auto On/Off button. IMPORTANT: The Pause button is functional in manual mode however miles driven during Pause mode will not be added to total miles driven while operating with manual ground speed enabled. Flex4 Control System 11001-1576-201103 OPERATION / 35 OPERATOR’S MANUAL NOTE: If manual mode is not accessible, manual speed access has been set to off in the program mode. Figure 33 Operate Screen with Manual Mode Enabled Manual Override Enabled AUTOMATIC MANUAL CONTROL CHANNEL OVERRIDE When an application rate sensor or flow meter failure occurs, the system reverts to automatic manual override and continues to operate the control channel in a manual override state. Manual override allows material to be spread at the same programmed rate without interruption. When a failure occurs, the rate decreases to “0” and “Manual” replaces the material name. Rate returns from “0” back to target rate while manual override is enabled. NOTE: Accuracy of material application rates will be affected due to the loss of rate feedback sensor. 36 / OPERATION Figure 34 Manual Control Channel Override MANUAL MANUAL 0.0 0.0 MANUAL MANUAL 550 13.0 Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL DRIVER LOGIN The Driver Login screen displays a list of up to 20 drivers created by an authorized user. The Driver Login screen automatically displays if a login is required when the system is powered on. The Operate screen will display after the passcode is entered. NOTE: If it is important to log data by driver, verify that the Driver Login function is enabled at the (F12) Data Logging screen. To Login: 1. At the Driver Login screen, select the respective number for the driver operating vehicle. 2. Enter the passcode for the driver. – Use the Back button to correct an incorrect passcode entry. 3. Press the Enter button to accept the passcode and display the Operate screen. Figure 35 Driver Login Screen To Logout: 1. At the Operate screen, press the Logout button. The driver is automatically logged out and displays the Driver Login screen for the next driver. NOTE: If the Route Selection button does not appear on the Operate screen, it has not been enabled at the (F12) Data Logging screen. NOTE: Miles, hours, and spread totals are logged by route and viewable at the Totals screen. Flex4 Control System 11001-1576-201103 ROUTE SELECTION The Route Selection screen lists up to 20 routes created by an authorized user in setup mode. A route can be selected from the list and will appear on the Operate screen. To Select a Route: 1. At the Operate screen, press the Route Select button to display the Route Select screen. 2. Select the desired route by pressing the respective Route (1-20) button. The only routes that appear are those created at the Data Logging screen. Once the route is selected, the screen automatically returns to the Operate screen with route name listed. 3. To remove the route from the Operate screen, return to the Route Select screen and press the No Route button. OPERATION / 37 OPERATOR’S MANUAL Figure 36 Route Selection Screen BOOM SECTION CONTROL Boom section control buttons appear on the Operate screen when ground speed is greater than zero. Button state indicates action to occur when pressed. To enable Boom Section Control: • • • NOTE: Refer to page 61 to enable boom section control feature. Press the Section ON button(s) to turn on. When a section is turned on, the button changes to a Section OFF button. Each section can be turned on and off independently. Spray nozzle graphics indicate active state. Any nozzle that is active displays in green and a nozzle that is inactive displays in red. Figure 37 Boom Section Control Button indicates action to occur when pressed 38 / OPERATION Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL ANTI-ICE FEATURE An Anti-Ice button appears on the Operate screen when a channel is enabled for anti-ice material. Activating the anti-ice feature automatically turns granular and liquid channels off to spread anti-ice material. Deactivating anti-ice stops spreading anti-ice material and automatically turns the granular and liquid channels on again. To activate Anti-Ice: 1. At the Operate screen, press the Anti-Ice On button. 2. Press the Anti-Ice Off button to deactivate. Figure 38 Anti-Ice On/Off Feature Granular and Liquid channels are ON Anti-Ice OFF Granular and Liquid channels are OFF Anti-Ice ON ACCESSORY SENSORS A dedicated accessory window at screen bottom of the Operate screen displays the enabled accessory sensors. When operating within normal ranges, the sensor status appears in green text. When the pre-defined limits exceed the normal ranges, an audible alarm beeps with an alarm message and the sensor status flashes in red. Operation can continue when a sensor is in an alarm state and the sensor status remains in red until normal ranges are met. OUTPUT MODULE ACCESSORIES An accessory connected to an output module and enabled at the (F11) Output Module screen can be monitored and controlled at the Operate screen. Front/Rear Conveyor • Flex4 Control System 11001-1576-201103 The Front/Rear Conveyor button toggles between front and rear operation. A graphic indicates the current active state. OPERATION / 39 OPERATOR’S MANUAL Figure 39 Front/Rear Conveyor Button and Graphics REAR Gate Increase/Decrease • • If gate height is increased, the conveyor speed decreases. If gate height is decreased, the conveyor speed increases. Figure 40 Gate Increase/Decrease Buttons Left/Right Spinner • Left/Right Spinner button toggles between activating the left spinner, right spinner, or both left and right spinner. Figure 41 Left/Right Spinner LEFT 40 / OPERATION RIGHT Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL HYDRAULIC ACCESSORY TOOL OPERATION To control an accessory tool during operation, press the Rate Increase/ Decrease buttons on the switch control module to increase and decrease the hydraulic flow. The PWM signal percentage sent to the hydraulic valve displays in the channel window. Accessory tools shut off when: – Ground speed reaches zero – or the Auto On/Off switch is turned off. An increase in ground speed activates the tool to the previous PWM percentage. The control channel is set to Manual without Feedback for this feature. Refer to Granular Configuration Setup (F2). Figure 42 Operate Screen with Manual Percentage Reading Control Channel Salt set for Manual w/o Feedback CURRENT AND SEASON RUN TOTALS The Totals screen provides accumulated material usage, miles, and hours driven using Auto mode, Blast, and Pause functions. Total operating data can be viewed in current run totals, season run totals, or by route. NOTE: Totals by driver are viewable only by exporting the data file to a report software tool program. Run totals are logged and recorded in the following ways: • • • • • • • Flex4 Control System 11001-1576-201103 Total Miles (km), tons (metric/English), and gallons (liters) spread while in automatic control mode for each control channel and product spread. Miles (km), tons (metric/English), and gallons (liters) spread while in Blast mode for each product spread. Total vehicle miles (km) driven Liquid gallons (liters) sprayed during prewetting and anti-icing application Total time spent spreading granular, spraying liquid, and blasting Miles (km), tons (metric/English), and gallons (liters) spread while in Pause mode Trip Log indicates total miles driven in Operate mode OPERATION / 41 OPERATOR’S MANUAL To view Totals: At the Operate screen, press the Totals button. 1. Current, Season, and Route button toggles between Current, Season, and Route run total screens. 2. Material Type Select button toggles between granular and liquid materials. 3. Material Select button scrolls through and displays totals for each material. 4. To reset totals, press the Reset Current Material button. 5. Reset Trip Log button clears accumulated miles to zero. 6. Route Select button toggles and displays totals for each route. 7. Back button returns to previous screen. Figure 43 Total Screen 1 4 5 2 3 6 7 42 / OPERATION Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL FLEX4 PROGRAMMING A keyboard is required to program and calibrate the system. The keyboard is removed after programming is complete. System will not allow entry of setup menus, calibration, or configuration without a keyboard attached. Function keys (F1 through F12) located at the top of the keyboard are used to display 12 menu screens that define desired system settings. Configuration parameters can be changed on menu screens by using the up and down arrow keys on the keyboard. Access to menus using keyboard function keys include: • • • • • • • • • • • • F1 Operate screen F2 Granular Channel Setup F3 Liquid Channel Setup F4 Spinner Setup F5 Auxiliary Channel Setup F6 Calibration F7 Diagnostics F8 Ground Speed Setup F9 Accessory Sensor Setup F10 System Setup F11 Output Module Setup F12 Data Logging PASSCODE RESTRICTIONS Two types of passcodes are optional and can be enabled to require a driver/ supervisor to-• • Login with a passcode before driver operation is allowed Login to gain access and change configuration setup values with a keyboard The system passcode settings are shipped as disabled. Passcodes can be enabled at the (F10) System screen (Driver Login Setup). Once passcode settings are enabled, the codes will be required before a driver begins operation or configuration setup screens are accessed. Passcodes can be any combination of numbers up to 10 digits. Flex4 Control System 11001-1576-201103 FLEX4 PROGRAMMING / 43 OPERATOR’S MANUAL USING THE KEYBOARD Programming is performed when the truck is stationary and the system is off. 1. Attach keyboard to terminal at the USB connection on the side of the terminal. Figure 44 USB Port USB port KEYBOARD FUNCTIONS (1) Function labels identify each function button (2) Function button displays menus for respective functions (3) Number buttons are used to select parameters from menu list and to insert values (4) Alpha buttons are used to create text labels and to make selections (5) Enter button accepts an entry and opens a window for text fields if more than one selection is available for a parameter (6) Escape button returns to the previous menu NOTE: A value on the screen is changed by using the up/down arrow keys on the keyboard to highlight a function box . Figure 45 Keyboard Layout and Functions 6 1 2 3 GRANULARGRANULAR LIQUID APPL OPERATE APPL CONFIG. RATE RATE Esc F2 F1 F3 @ 2 ! 1 # 3 ^ 6 T R SPINNER F7 F6 % 5 E GROUND SPEED CAL F5 $ 4 W Q LIQUID CONFIG. F4 ACCUM F8 & 7 * 8 7 Y 4 A F11 8 ( 9 ) 0 U D F G H Z Ctrl X Alt C ~ ` V B 6 M _ Alt " Pause Break Back Space Home Enter Enter ? / Ins Scroll Lock | \ + > . 0 } ] { [ : 3 < , PrtSc SysRc + = - * P 2 Num Lock _ L K MISC. F12 O 5 J N 9 I 1 Shift Fn S SYSTEM RESP. F10 4 Caps Lock SYSTEM INFO. F9 Shift 5 PgDn End / Del TM 44 / FLEX4 PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL TEXT ENTRIES 1. Press Enter to open a text window on the screen to display all possible selections. 2. Use the Up/Down Arrow buttons to highlight and select the desired parameter. 3. Press Enter to accept. Figure 46 Open a Text Window Press ‘Enter’ to open text window Flex4 Control System 11001-1576-201103 FLEX4 PROGRAMMING / 45 OPERATOR’S MANUAL LABEL ENTRIES 1. To create label names, such as a Material Name, highlight the field and begin typing the name. A virtual keyboard displays onscreen and the name as entered will appear at top of the virtual keyboard. 2. Press the Enter button to accept the label entry. NOTE: The Enter button will not select a text field. Figure 47 Virtual Keyboard Using the keyboard up/down arrow buttons select and highlight a parameter Material Label 46 / FLEX4 PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL NUMBER ENTRIES 1. To enter a number value, highlight the field and begin typing numbers from the keyboard. A virtual keypad display onscreen and the number, as entered, will appear at top of the virtual keypad. 2. Press the Enter button to accept the label entry. Figure 48 Virtual Keypad 2500.0 Number Keypad Flex4 Control System 11001-1576-201103 FLEX4 PROGRAMMING / 47 OPERATOR’S MANUAL 48 / FLEX4 PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL SYSTEM PROGRAMMING The Flex4 Ice Control system has configuration screens to enter user-defined rates, limits, and parameters for regulating system product application. Four channels are available for material and spinner control: • • • • (1) dedicated granular channel (F2) (1) dedicated liquid channel (F3) (1) dedicated spinner channel (F4) (1) auxiliary channel to setup an additional liquid or granular channel (F5) Additional setup for proper system operation includes performing: • • • • • • • System Calibration (F6) Diagnostics (F7) Ground Speed Setup (F8) Accessory Sensor Setup (F9) System Setup (F10) Output Module Setup (F11) Data Logging (F12) IMPORTANT: System programming MUST be conducted before performing a system calibration. Accurate system calibration constants are determined through regular calibration routines. Known constants can be entered reducing the calibration procedures required. Calibration corrections can be performed anytime to fine-tune accuracy. OPERATE MODE (F1) The Operate screen can be accessed at anytime during programming by pressing the F1 function key. No programming functions are available at this screen but can be used to verify active selections. The Operate screen shows programmed values for spreading material and provides access to the following functions: • • • • Material Selection screen Unloading Material screen Virtual Terminal Display settings Current Totals screen Refer to the Operation section for detailed function descriptions. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 49 OPERATOR’S MANUAL GRANULAR CHANNEL SETUP (F2) Granular channel setup screen defines the set of values of four material application rates, min/max limits, and blast rates as well as the configuration parameters for hydraulic valves and sensors. Granular channel parameters include: • • • • • • Material Label Units Spreader Constant Calibration Gate Height Application Rate Method (Step or Rate) Blast Rate The channel’s current status is displayed as Enabled or Disabled. To Change the Channel’s Status: 1. Use the up or down arrow keys on the keyboard to select and highlight the function box. 2. Press the Enter key and select the desired function status as either Enable or Disable. 3. Press the Enter key to accept. 4. To define material rates, press the respective item number (1 - 4) using the keyboard to display the Granular Rates screen. 5. Press the Enter key to open a menu selection box to display and select the appropriate parameters. Figure 49 Granular Channel Setup STEP METHOD 50 / SYSTEM PROGRAMMING RATE METHOD Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL GRANULAR RATE SETUP MATERIAL LABEL A user-defined material name entered (10 characters maximum) that identifies the material configured for a channel on the Operate screen. UNITS Unit of measure for granular material are available in the following parameters: – – – – – – lbs (kilograms) per mile (km) lb/mift lbs per sq ft/grams per sq meter lbs per sq yd/meter lbs/kft2 lbs per acre SPREADER CONSTANT Represents the number of pulses generated by the application rate sensor per pound of material (P/LB) discharged from the spreader. The spreader constant varies for each granular material, spreader vehicle, and gate height setting (if optional gate height sensor is installed and enabled). If the spreader constant is known, the value can be manually entered via a keyboard with no granular calibration required. For unknown spreader constant values, a granular calibration should be performed. CALIBRATION GATE HEIGHT Calibration Gate Height displays only if the gate height sensor is enabled at the Accessory Sensor screen (F9). If enabled, the calibration gate height valve displayed is the setting of the gate height (inches) as a result of a performed spreader calibration. IMPORTANT: The Gate Height must be enabled before a spreader calibration is performed. Refer to the Spreader Calibration procedure. The original calibrated gate setting can be changed to provide a more accurate granular material application by adjusting the conveyor speed. – An increased gate height decreases conveyor speed – A decreased gate height increases conveyor speed If the sensor voltage is outside the range between the Closed and Open position values, the display will state Gate Low or Gate High. If Gate Low displays, the signal from the sensor is exceeding the open voltage. In either case, an alarm will activate. The Gate Height should be checked and set at the granular calibration it was ran for on that granular channel. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 51 OPERATOR’S MANUAL APPLICATION RATE METHOD Two methods are available to control the application of material: • • Step Method Rate Method Step Method Allows rates to be changed by a fixed increment using the Rate Increase/ Decrease buttons on the switch module. NOTE: Rate changes only occur when the material is selected/ highlighted on the Operate screen. To select the Step Method: Maximum Rate establishes the maximum application rate in KS (thousand) seeds per acre or (KS/Ha) that the control allows. Target Rate cannot be incremented to a value greater than this established Max Rate. 1. Highlight the Step method selection box and press the Enter key on the keyboard. 2. Select Yes and press the Enter key again. 3. Enter the desired target rate (lbs/mile) for material application to be controlled by this channel. 4. Enter a minimum application rate limit for this channel. Minimum rate establishes the minimum application rate that the control allows. Target rate cannot be decremented to a value lower than this established Min Rate. 5. Enter a maximum application rate limit for this channel. Maximum rate establishes the maximum application rate that the control allows. Target rate cannot be incremented to a value greater than this established Max Rate. 6. Enter an Increase/Decrease Step value that sets the increase/ decrease rate. The increment/decrement percent rate establishes the percentage of change of the entered target rate that is applied each time the Rate Increase/Decrease button is pressed. NOTE: The maximum or minimum rates may not be reached if the % increase or decrease, based off the target rate, exceeds the maximum or minimum rate limits set. 52 / SYSTEM PROGRAMMING 7. Enter a desired blast rate that applies a higher-than-normal, spot application when the Blast button is pressed during operation. Figure 50 Step Method Screen Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL To select the Rate Method: Rate Method allows ten user-defined application rates to be entered. Rates can be adjusted during operation using the Rate Increase/Decrease buttons on the switch module. 1. Highlight the Step method selection box and press the Enter key on the keyboard. 2. Select No and press the Enter key again. 3. Enter desired rates (Rates 1-10). If less than 10 rates are desired, enter a zero (0) for each rate following the last programmed rate. The initial rate displayed during operation is Rate 1. Other rates are selected by pressing the Rate Increase/Decrease button on the switch module. 4. Enter a desired blast rate that applies a higher-than-normal, spot application when the Blast button is pressed during operation. Figure 51 Step Method Screen BLAST RATE A Blast Rate (lbs per mile) defines a higher than normal spot-application rate that is applied when the Blast button is pressed. A time and speed to simulate the length of time and ground speed to apply material when the vehicle is stationary can be entered at the (F10) System Setup screen. When the Blast Speed is set to zero, blasting cannot be initiated when the vehicle is stopped. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 53 OPERATOR’S MANUAL GRANULAR CONFIGURATION (F2) Configuration parameters defined for each channel correlate with the types of hydraulic valves and sensors installed and related performance specifications. These values should not change unless system hardware is modified or related calibration routines are performed. IMPORTANT: A calibration should be performed for each channel prior to operating to ensure accurate material application. To enter Configuration Values: 1. At the F2 Granular Setup screen, press 5 on the keyboard. 2. At the Granular Configuration screen, highlight the control mode selection box and press the Enter key to select Auto or Manual with Feedback. 3. Press the Enter key to confirm the selection. 4. Use the keyboard arrow keys to scroll to each constant’s selection box. Figure 52 Granular Configuration Screen CONTROL MODE MANUAL WITH FEEDBACK Overrides the current system when not operating properly. Using the Rate Increase/Decrease buttons during operation sets the RPM rate for the control channel. Actual RPM rate displays based on actual ground speed and spreader constants entered. MANUAL WITHOUT FEEDBACK Typically used when operating with an accessory tool, such as a front sweeper, using a PWM signal to open and close the valve. The Increase/ Decrease buttons are used to increase/decrease the hydraulic flow to the accessory tool and a PWM percentage on the Operate screen indicates the PWM signal sent to the hydraulic valve. 54 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL AUTO Control channel calculates application rates based on ground speed and signal feedback from the application rate sensor (closed loop control) under normal operating conditions. DRIVE FREQUENCY Drive Frequency specifies the frequency for the proportional valve. The recommended setting is defined by the specific valve manufacturer. PWM OFFSET PWM Offset identifies the minimum amount of PWM valve drive required to start the granular mechanism. PWM SATURATION PWM Saturation identifies the amount of drive the granular valve system requires to operate a PWM valve at full speed. SYSTEM RESPONSE Adjusts the control system response time to the hydraulic and mechanical systems of the granular control channel on each particular spreader vehicle. VALVE BOOST Increases the amount of system response initially applied to the granular control to reach final operating speed as quickly as possible. AFILT Filters the feedback signal to minimize the effect of electrical noise and mechanical vibrations. The smaller the number, the greater degree of filtering. MATERIAL Selection of the four materials that are configurable for the channel. SENSOR CONSTANT Sensor Constant establishes the number of pulses for one revolution of the application rate sensor. If a standard DICKEY-john application rate sensor is used, the value should be set to 360.0. SPREADER CONSTANT The Spreader Constant displayed value is viewable only and indicates the current setting. This value automatically adjusts when a granular calibration is performed. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 55 OPERATOR’S MANUAL CALIBRATION GATE HEIGHT Calibration Gate Height only displays if enabled as an accessory sensor at the (F9) Accessory Sensor screen. This value is viewable only and indicates the current setting. The value automatically adjusts when a granular calibration is performed. 56 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL LIQUID CHANNEL SETUP (F3) Liquid channel setup allows configuration of up to four different liquid materials, entry of the material parameters, and to identify the performance specifications of the installed actuators and sensors. Each material can be set with different parameters. The liquid channel can be set as either Prewet (gal/ton) (spraying with a pre-wet spray bar), Anti-ice (gal/mile) (used with anti-icing boom), or Liquid (gal/area). Liquid channel parameters include: • • • • • Material Label Units K Factor Application Rate Method (Step or Rate) Blast Rate The channel’s current status is displayed as Enabled or Disabled. To Change the Channel’s Status Function: 1. Use the Up or Down Arrow keys on the keyboard to select and highlight the Function box. 2. Press the Enter key and select the desired function status as either Prewet, Liquid, or Disable. 3. Press the Enter key to accept. 4. To setup material parameters for Materials 5-8, select items 1-4 using the keyboard. Figure 53 Liquid Channel Setup Screen Boom selection only displays when a channel is set for liquid application. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 57 OPERATOR’S MANUAL LIQUID RATE SETUP Each material assigned to the liquid channel requires entry of material parameters. Figure 54 Liquid Application Units for Prewet configuration only displays in (GAL/TON-US or L/TON-Metric) MATERIAL LABEL A user-defined material name entered (10 characters maximum) that identifies the material configured for a channel on the Operate screen. UNITS The unit type selected displays material application rate as follows: gal/mile - Miles per gallon gal/mift - Foot traveled per mile gal/ft2 - Square feet per gallon gal/yd2 - Square yards per gallon gal/kft2 - Thousand square feet gal/ac - Gallons per acre K FACTOR K Factor represents the number of flow meter pulses generated by the sensor per gallon/liter of dispersed liquid for pre-wet and anti-icing liquids through the flow meter. The K Factor number stamped on the flow meter body is sufficiently accurate for keyboard entry if the viscosity of the liquid is near that of water. If the flow meter constant is unknown, the actual value will adjust to the correct constant during the liquid calibration. 58 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL APPLICATION RATE METHOD Two methods are available to control the application of material: • • STEP Method Rate Method STEP Method STEP Method allows rates to be changed by a fixed increment using the Rate Increase/Decrease buttons on the switch module. STEP method requires a Target Rate, Min/Max Rate, and Inc/Dec Step defined. To select the STEP Method: Maximum Rate establishes the maximum application rate in gallons per mile (L/km) that the control will allow. Target Rate cannot be incremented to a value greater than this established Max Rate. 1. Highlight the Step method selection box and press the Enter key on the keyboard. 2. Select Yes and press the Enter key again. 3. Enter the desired target rate for material application to be controlled by this channel. 4. Enter a minimum application rate limit for this channel. 5. Enter a maximum application rate limit for this channel. 6. Enter an Increase/Decrease Step value that sets the increase/ decrease rate. IMPORTANT: The maximum or minimum rates may not be reached if the % increase or decrease, based off the target rate, exceeds the maximum or minimum rate limits set. 7. Enter a desired blast rate that applies a higher-than-normal, spot application when the Blast button is pressed during operation. Figure 55 STEP Method Enabled TARGET RATE Target rate establishes the desired amount of material to be applied in gallons/mile by a control channel. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 59 OPERATOR’S MANUAL MINIMUM/MAXIMUM RATE The minimim and maximum rates establish the minimum and maximum application rates that the control will allow. Target rate cannot be decremented to a value lower than this established minimum and maximum rates. INC/DEC STEP The increment/decrement percent rate establishes the percentage of change of the entered target rate that is applied each time the Rate Increase/Decrease button is pressed. BLAST RATE Blast Rate defines a higher than normal, spot-application rate applied when the Blast button is pressed. Rate Method: Rate Method allows ten user-defined application rates to be entered. Rates can be adjusted during operation using the Rate Increase/Decrease buttons on the switch module. To select the Rate Method: 1. Highlight the Step method selection box and press the Enter key on the keyboard. 2. Select No and press the Enter key again. 3. Enter desired rates (Rates 1-10). If less than 10 rates are desired, enter a zero (0) for each rate following the last programmed rate. The initial rate displayed during operation is Rate 1. Other rates are selected by pressing the Rate Increase/Decrease button on the switch module. 4. Enter a desired blast rate that applies a higher-than-normal, spot application when the Blast button is pressed during operation. Figure 56 Rate Method Enabled 60 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL BOOM CONFIGURATION Boom Configuration screen identifies how the unit is controlling or monitoring boom sections and assigns boom sections to a liquid or auxiliary channel. A total of 6 boom sections can be controlled by the system. A DICKEY-john output module must be installed to support boom control. To assign Boom Sections: 1. At the (F3) Liquid Menu screen, select 6 on the keyboard to display the Boom Configuration screen. 1. Select the function type as either Control or Sense. 2. Select the active level output signal as either Ground or 12V. 3. To change the default name for each boom label, press the respective number (1-6) and type the new label name in the virtual keypad. 4. Add the width of each boom section. 5. Select the channel type that controls each boom label. NOTE: Anti-ice and pre-wet channel types do not require a width entry and the width column will not appear in those instances. Figure 57 Boom Configuration Screen FUNCTION NOTE: Contact DICKEY-john Technical Support at 1-800-637-3302 to order a DICKEY-john output module. Control Boom sections are controlled by a DICKEY-john output module allowing sections to be turned on and off at the Operate screen with assigned section buttons. Sense Boom sections are controlled by a separate switch box. Boom sections are only sensed by the unit and displays on or off status on the Operate screen. ACTIVE LEVEL Active level sets the output signal as either Ground or 12V for a valve driver to control a boom shutoff delay. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 61 OPERATOR’S MANUAL SPINNER CONFIGURATION (F4) Spinner constants set the parameters and performance specifications for installed actuators and sensors. These values do not change unless the system hardware changes or the related calibration routines are re-run. To enter Spinner Configuration Values: 1. At the F4 Spinner Configuration screen, use the up or down arrow keys on the keyboard to select and highlight the function box to enable or disable. 2. Enter parameter values per below definition. Figure 58 Spinner Configuration Screen SPINNER UNITS Spinner units set the spread width bar graph to display in percent, feet, or RPM. Pulse Feedback must be set to YES for the spinner units to be selected as RPM. If a spinner spread width calibration is required, spinner units must be selected as feet to perform the calibration. UNLOAD Enable the Unload feature by selecting Yes to activate the spinner during unloading. Select No to disable during the unload process. DRIVE FREQUENCY Drive Frequency specifies the frequency for the installed proportional valve. The recommended setting for this option should be specified from the valve manufacturer. NO GROUND SPEED Select Yes to allow the spinner to continue running when there is no ground speed. Select No for the spinner to stop running when there is no ground speed. 62 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL BLAST RATE A Blast Rate percentage greater than zero percent sets the maximum spinner speed when Blast is pressed regardless of any adjustment to the spread width knob. A Blast Rate percentage set at zero places no constraints on the maximum spinner speed when using the spread width knob. PULSE FEEDBACK Enable Pulse Feedback by selecting Yes for closed-loop control. Disable Pulse Feedback by selecting No for open-loop control. SPINNER CONSTANT Spinner Constant establishes the number of pulses for one revolution of the spinner. Spinner Constant appears only when Pulse Feedback is enabled. PWM OFFSET PWM Offset identifies the minimum amount of PWM valve drive required to start the liquid mechanism. PWM SATURATION PWM Saturation identifies the amount of drive the liquid valve system requires to operate a PWM valve at full speed. SYSTEM RESPONSE Adjusts the control system response time to the hydraulic and mechanical systems of the liquid control channel on each particular spreader vehicle. VALVE BOOST Increases the amount of system response initially applied to the liquid control to reach final operating speed as quickly as possible. AFILT Filters the feedback signal to minimize the effect of electrical noise and mechanical vibrations. The smaller the number the greater degree of filtering. GROUND SPEED RELATED To regulate the spinner speed related to ground speed and run closed enable by selecting Yes. Controlling the spinner according to ground speed allows the material to disperse at zero velocity. GSRS SLOPE When GSRS is enabled, GSRS Slope indicates the spinner revolutions per mph/kmh on the Operate screen. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 63 OPERATOR’S MANUAL MAXIMUM GSRS When GSRS is enabled, Max GSRS determines the scaling of the spinner bar graph on the Operate screen. A full bar graph indicates that the maximum GSRS speed has been exceeded in mph/kph. No alarm is associated with this constant. AUXILIARY CONTROL CHANNEL CONFIGURATION (F5) The Auxiliary control channel has the flexibility to be programmed as a Liquid, Granular, Prewet, or Anti-Ice channel with the same parameter setup available as channels one and two. Four additional materials can be added to the auxiliary channel. Configuration and boom setup for an auxiliary channel must be enabled at this screen for the channel to be in an active state. Refer to the Granular Configuration (F2) and Liquid Configuration (F3) sections for parameter definition and setup instructions. Press the Calibration (F6) key to initiate channel calibration. Figure 59 Auxiliary Control Channel Screen 64 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL ACCESSORY SENSORS (F9) Accessory sensor screen sets the parameters for installed sensors that can be monitored, when enabled, on the Operate screen. All accessory sensors are set to disabled and must be enabled and may require calibratation. Up to four analog sensors can be enabled at one time. Analog sensor types include: • • • • • Gate height Bed height Road/Air temperature (requires the Flex4 interface cable and RoadWatch Temperature Adapter that connects to any of the analog 1-4 positions on the Rate Control Module harness. Tank level Down pressure Two digital accessory sensors can be enabled at one time. In addition to configuring accessory sensors, an installed DICKEY-john joystick’s active position can be viewed on the Operate screen when enabled at this screen. To enable Accessory Sensors: 1. At the (F9) Accessory menu screen, highlight the Analog Acc Sensor input box and press the Enter key to open the sensor drop down list. 2. Select the sensor and press Enter. 3. To open the Sensor Configuration screen of the selected sensor, press the corresponding key (1 - 6) to select a menu item. Refer to (Figure 60). IMPORTANT: The RoadWatch Sensor adapter must be connected to an additional adapter cable that connects to the Rate Control Module harness. The adapter cable must be connected to the connectors labeled as Analog 1, 2, 3 or 4 . The connection point for the road temperature and air temperature must be identified at the F9 Accessory Sensor screen. Figure 60 Accessory Sensors Screen Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 65 OPERATOR’S MANUAL GATE HEIGHT SENSOR A gate height sensor compensates for changes from the original calibrated gate setting by adjusting the conveyor speed for a more accurate granular material application. If the gate height is increased, conveyor speed decreases and a decreased gate height increases the conveyor speed. Gate Height status appears on the Operate screen as GATE 0.0 IN. Figure 61 Gate Height Sensor PRESS C TO CAPTURE VOLTAGE GATE HEIGHT CALIBRATION Gate height calibration captures the voltage range of seven gate height positions from the closed to open positions that are used when spreading material. To perform a Gate Height Calibration: 1. 2. 3. 4. Select YES to enable gate height. Highlight the Closed Inches column. Set the gate to the closed position. Measure the height at the closed position and enter that amount in inches in the Closed input field. 5. Press “C” to capture the current gate height voltage at the closed setting. The voltage automatically is calculated and entered at each position. 6. Repeat steps 3 through 5 for each position. The gate should be at the full open height to measure at the Open position. If the sensor voltage is outside the range between the closed and open position values, the display will state Gate Low or Gate High and an alarm activates. The gate height should be checked and set at the granular calibration it was ran for on that granular channel. If the gate height is enabled and calibrated, all of the desired granular materials that are enabled must be recalibrated through a material drop test. If enabled materials are not calibrated, the system will alarm. 66 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL ROAD TEMPERATURE SENSOR A road temperature sensor monitors road temperature changes. When enabled, an alarm on the Operate screen identifies when defined road temperature changes occur. IMPORTANT: The RoadWatch Sensor adapter must be connected to the Flex4 Interface cable that connects to the Rate Control Module harness. The Interface cable must be connected to the connectors labeled as Analog 1, 2, 3 or 4. The connection point for the road temperature and air temperature must be identified at the F9 Accessory Sensor screen. Road Temperature status appears on Operate screen as: 67F ROAD TEMPERATURE AIR 75F To enable Road Temperature Values: 1. At the Road/Air Temperature Menu screen, select the corresponding number. 2. Select Yes at the Temperature Enabled input box. 3. Enter the alarm temperature in degrees F to alert of road temperature changes to indicate when application rate or material changes are required. Temperatures must be entered in descending order with Alarm Temp 1 the highest setting and Alarm Temp 3 the lowest setting. 4. Enter the temperature hysteresis that will clear the temperature alarm when a positive temperature change has occurred. If Alarm Temp 1 is 20 degrees F and the Temperature Hysteresis is set at 5 degrees F, the alarm activates when the temperature drops below 20 degrees F and clears when the temperature reaches 25 degrees F. 5. The High and Low Calibration values should not be changed and should be created from the calibration routine. 6. After values are entered, press C to begin the calibration procedure. Calibration lasts approximately 10-20 seconds. 7. Press “D” when done. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 67 OPERATOR’S MANUAL Figure 62 Road Temperature Sensor IMPORTANT: The RoadWatch(TM) temperature sensor or Surface Patrol(TM) temperature sensor must be disconnected and the Flex4 Interface cable and the DICKEY-john temperature sensor adapter connected to the main harness for successful calibration. If the interface cable and the DICKEY-john temperature sensor adapter is disconnected when the calibration is performed, an error screen displays. NOTE: Road Watch TM is a registered trademark of Commercial Vehicle Group TM. Surface Patrol Technology is a registered trademark of Control Products Inc. 68 / SYSTEM PROGRAMMING Figure 63 Road Temperature Sensor Calibration Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL AIR TEMPERATURE SENSOR An air temperature sensor monitors air temperature changes. When enabled, an alarm on the Operate screen identifies when defined air temperature changes occur. Refer to Road Temperature section for display appearance on Operate screen. To enable Air Temperature Sensor Values: 1. Air temperature sensor input values and calibration procedures are similar to road temperature sensors. Refer to Road Temperature Sensor section for entering values. NOTE: The RoadWatch(TM) temperature sensor or Surface Patrol(TM) temperature sensor must be disconnected and the DICKEY-john temperature sensor adapter connected to the main harness for successful calibration. If the DICKEY-john temperature sensor adapter is disconnected when calibration is performed, an error screen displays. Figure 64 Air Temperature Sensor Screens IMPORTANT: The RoadWatch Sensor adapter must be connected to the Flex4 Interface cable that connects to the Rate Control Module harness. The Interface cable must be connected to the Rate Control Module connectors labeled as Analog 1, 2, 3 or 4. The connection point for the road temperature and air temperature must be identified at the F9 Accessory Sensor screen. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 69 OPERATOR’S MANUAL TANK LEVEL SENSOR CONFIGURATION The tank level sensor monitors the liquid level for pre-wet or anti-ice systems. To enable the Tank Level Sensor: 1. At the Tank Level Menu screen, select Yes at the Tank Level Enabled input box. 2. Tank level status can be displayed in a bargraph format (Yes) or percentage of approximate material remaining (No). 3. Highlight the Empty Voltage input box. The tank must be empty before performing the Empty Voltage calibration. 4. Press “C” to capture the empty voltage reading. 5. Fill tank to appropriate level. Highlight the Full Voltage input box. The tank must be full before performing the Full Voltage calibration. 6. Press “C” to capture the full voltage reading. IMPORTANT: It is recommended that voltages are automatically captured but manual entry of voltages can be entered. 7. Enter a tank level alarm percentage to warn when the tank level has reached the alarm limit. The value has a 5% hysteresis tolerance to prevent random alarming due to varying tank levels while driving. EXAMPLE: If the tank alarm is set for 10%, the alarm activates when the level drops below 10% but will not clear until the level reaches 15%. If the tank alarm is set for 100 gallons on a 1000 gallon capacity, the alarm activates when the level drops below 100 gallons but does not clear until the level reaches 150 gallons. The alarm sounds for the first five seconds and text will flash until the condition is cleared or another alarm sounds. Figure 65 Tank Level Sensor PRESS C TO CAPTURE VOLTAGE 70 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL DOWN PRESSURE A down pressure sensor monitors the relative pressure applied to the under body belly scraper. Down Pressure status appears on the Operate screen as: DWN PRES100% To enable the Down Pressure Sensor: 1. At the Down Pressure Menu screen, select Yes at the Down Pressure Enabled input box. 2. Highlight the Minimum Pressure input box. 3. Elevate the scraper before performing the minimum pressure reading calibration. 4. Press “C” to capture the minimum pressure reading. 5. Highlight the maximum pressure input box. 6. Position the scraper downward until road contact occurs and the desired normal road contact pressure is reached. This will set the 100% down pressure maximum value (next step). 7. Press “C” to capture the maximum voltage reading. IMPORTANT: It is recommended that voltages are automatically captured through the calibration but manual entry of voltages can be entered. 8. Enter a down pressure alarm percentage to warn when the down pressure is within the specified percentage of reaching the maximum down pressure limit. Figure 66 Down Pressure Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 71 OPERATOR’S MANUAL BED HEIGHT A bed height sensor activates when the bed has exceeded the recommended operating height. All mechanical linkages should be inspected and maintained on a regularly scheduled interval to ensure proper operation of the bed height alarm. Visual inspection of the bed height must be maintained as the primary indicator of safe bed height operation. The alarm should only be used as a secondary convenience indicator. The operator assumes all risk in using this feature. DICKEY-john assumes no responsibility for alarm failure to indicate an unsafe operating height. Bed Height status appears on Operate screen as: BED 113% To enable a Bed Height Sensor: 1. At the Bed Height Menu screen, select Yes at the Bed Height Enabled input box. 2. Highlight the Bed Down input box. The dump bed must be completely down and the sensor installed before performing the calibration. 3. Press “C” to capture the bed down reading. 4. Bed Alarm indicates the voltage when the bed has exceeded normal operating height and can be entered manually or automatically. 5. Highlight the Bed Alarm input box. The dump bed must must be near the maximum operating height and the sensor installed before automatic entry can occur. Press “C” to automatically capture sensor voltage. For manual entry, select the bed alarm text and enter the voltage when the bed exceeds the normal operating height. Figure 67 Bed Height Sensor Screen 72 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL DIGITAL ACCESSORIES Two digital sensors can be installed to monitor critical operation parameters on the vehicle. To enable a Digital Accessory Sensor: 1. At the F9 Accessory screen, press 6 or 7 to open a Digital Accessory screen. 2. Select Yes at the Digital Acc Enabled input box. 3. At the Sensor Type input box, select the appropriate sensor as digital, frequency, or camera. Sensor type determines what parameters appear on the screen. 4. Select the Active Level power supply as either 12V or ground. 5. Enter an appropriate active and inactive label that identifies the sensor type and status on the Operate screen. 6. Select the Alarm Mode as either Never, Auto, or Always. Figure 68 Digital Accessory Screens SENSOR TYPE DIGITAL and FREQUENCY - Select the sensor type as digital or frequency. CAMERA - Select camera to automatically view camera video on the display screen when it senses a 12V input. Typically used when the truck is placed in reverse and 12V is sensed; the camera automatically appears on the display. ACTIVE LEVEL Active level sets the sensor output signal as either Ground or 12V to sense the sensor as on or off. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 73 OPERATOR’S MANUAL ACTIVE LABEL A user-defined name that identifies the sensor type or function that displays on the Operate screen providing sensor status, i.e. active label name (HOPPER FULL). INACTIVE LABEL A user-defined name that identifies the sensor type or function that displays on the Operate screen providing sensor status, i.e., inactive label name (HOPPER LOW). ALARM MODE NEVER - Alarms are turned off and will not trigger an alarm condition during operation. AUTO - Alarm occurs after the defined alarm delay only when the system is active and controlling. ALWAYS - Alarm occurs after the defined alarm delay during operate mode and shutdown mode. ALARM DELAY Amount of time delay in seconds that occurs before an alarm is triggered based on user-defined sensor parameters. SYSTEM SHUTDOWN Select Enabled to shutdown the system from operating anytime an alarm is triggered. Figure 69 Accessory Sensor Screen (Frequency) LABEL A user-defined name that identifies sensor type and displays on the Operate screen providing sensor status. CONSTANT Constant establishes the number of pulses for one revolution of the application rate sensor. 74 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL OFFSET The Offset determines the units of which the constant is converting the frequency into. ALARM MODE NEVER - Alarms are turned off and will not trigger an alarm condition during operation. AUTO - Alarm occurs after the defined alarm delay only when the system is active and controlling. ALWAYS - Alarm occurs afterthe defined alarm delay during operate mode and shutdown mode. HIGH/LOW ALARM LIMIT The High and Low Alarm limit values determine when an alarm is triggered to warn when a certain condition is met that is set by user-defined parameters. ALARM DELAY Amount of time delay in seconds that occurs before an alarm is triggered based on user-defined sensor parameters. HIGH/LOW SHUTDOWN The system shutdowns automatically when High and Low Shutdown is enabled and the alarm condition is met as defined in High and Low Alarm Limits. Both High and Low Shutdown functionality is independent of each other. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 75 OPERATOR’S MANUAL JOYSTICK LABELS When a DICKEY-john joystick is installed, joystick labels can be created to indicate functions that are enabled or active. Joystick function appears on Operate screen as: SCRAPER To create Joystick Control Names: 1. At the (F9) Accessory menu screen, press 7 on the keyboard to display the Joystick Labels screen. 1. Select Yes at the Joystick Sense Enabled input box to indicate a DICKEY-john joystick is installed. 2. At each label input box, enter a user-defined name that correlates with the joystick function. Figure 70 Joystick Labels Screen 76 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL SYSTEM SETUP (F10) System setup defines the following parameters: • • • • • • • Blast Setup Date and Time Units and Language Service Troubleshooting GPS Sensor Wireless Configuration (not currently functional) To access the System Setup Screen: 1. Press the F10 key to display the System menu screen. 2. At the System Setup screen, press the respective item number to open a menu item. Figure 71 System Setup Screen BLAST SETUP 1. Press 1 on the keyboard to select Blast Setup. Figure 72 Blast Setup Screen Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 77 OPERATOR’S MANUAL BLAST TIMER Enter number of seconds for the length of the Blast cycle. When set to zero (0), the blast cycle lasts only as long as the Blast button is pressed. BLAST SPEED Establishes an artificial vehicle ground speed when vehicle is at standstill or moving slowly to compute the rate material dispenses during a blast cycle. – For speeds faster than this value, the actual vehicle ground speed determines the spread rate. – If Blast speed is set to zero, the screen will show a BLAST but no material will fall. DATE AND TIME The date and time of the unit is factory set to Central Standard Time. The time can be re-set to the appropriate time zone by entering in either 12 hour or 24 hour time. To set Date and Time: 1. At the F10 System menu screen, press the 2 key to display the Date and Time screen. 2. Select ‘Yes’ in the 24 Hour input box for a 24 hour clock setting. Select ‘No’ in the 24 Hour input box for a 12 hour (am/pm) setting. 3. At the Current Time input box, highlight the digits to change and type in the time. 4. At the Current Date input box, highlight the digits to change and type in the date. Figure 73 Date and Time Screen 78 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL UNITS AND LANGUAGE The system is equipped with a set of various languages that display the user screens in the language selected. Language default is English (US). Available Languages: • • English Additional languages will be available on future releases. Contact Technical Support at 1-800-637-3302 for release dates and available languages. Units of measurement available: • • US Metric To enter Units and Language: 1. At the (F10) System menu screen, press the 3 key to display the Units and Language screen. 2. Select Yes to enable metric as the unit of measurement. Default is set to English. 3. The current language setting of English cannot be adjusted. Figure 74 Units and Language Screen Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 79 OPERATOR’S MANUAL SERVICE The Service menu is typically used by authorized personnel to incorporate product enhancements, troubleshoot, and identify the system’s current software version. 1. Press 4 on the keyboard to select the Service menu screen. SOFTWARE VERSION 1. Press 1 at the Service screen to display the system’s installed software version. Figure 75 Software Version Screen 80 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL SYSTEM RESET 1. Press 2 at the Service menu screen to reset system parameters to default factory values. 2. A confirmation screen prompts a Yes or No selection before the system reset occurs. Figure 76 System Reset Screen Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 81 OPERATOR’S MANUAL TROUBLESHOOTING Troubleshooting screens provide access to System Response screens relating to spinner and material channels. IMPORTANT: It is recommended that these parameters not be modified as any changes could affect performance. Contact DICKEY-john Technical Support at 1-800-637-3302 for assistance. 1. At the (F10) System menu screen, press 5 on the keyboard to display the Troubleshooting screen. 2. Select the corresponding number to view the material or spinner channel system parameters. Figure 77 Troubleshooting Screen 82 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL GPS SENSOR If a GPS sensor is installed, it must be enabled at the GPS Sensor screen. GPS coordinates with a time and date recording of the following events are stored in the terminal: • • • • • • When truck was started and turned off, type of material spread, and application rates selected by operator When control system was operating in an error condition, such as application error, manual override, or loss of feedback sensor When the control system exceeded the vehicle maximum speed alarm set point When control was in automatic mode of control versus off When blast and pause function was activated GPS coordinates of location by time and date Log GPS Position per Event This feature must be enabled to log events with GPS position and coordinates in the data log file. GPS coordinates are stored in the log data file for use in an data management software reporting package for vehicle tracking. If this feature is disabled, a sequence of events, miles driven, distance, and speed are recorded with no GPS coordinates. To enable GPS Sensor: 1. At the (F10) System menu screen, press 6 on the keyboard to display the GPS Sensor screen. 2. Select Yes to indicate a GPS sensor is installed. 3. Select Yes to log GPS position and coordinates by event. Figure 78 GPS Sensor Screen Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 83 OPERATOR’S MANUAL OUTPUT MODULE SETUP (F11) An optional output module connects to the master control module via a CAN BUS to control additional installed accessories. A 10 foot accessory harness extension is available that connects the Output Module harness to the Rate Control harness, if required. Accessory functions include: • • • • Boom section shutoff valves Open and close V-Box gates Switching valves for front/rear conveyors Switching valves for left/right discharge cross conveyors To enter Output Module Setup: 1. 2. 3. 4. 5. Press F11 to display the Output Module screen. Select Yes if a 12V output signal is used. Select Yes to control the left and right conveyor. Select Yes to control raising and lowering the gate height from the cab. Enter the increase/decrease PWM% that determines how fast the gate opens and closes. 6. Enter the increase/decrease time that affects the speed of opening and closing the gate. Figure 79 Output Module Setup Screen FRONT/REAR CONVEYOR Select Yes to control the front and rear conveyor position during operation by selecting the front and rear conveyor buttons available on the Operate screen. Current conveyor position is displayed on the Operate screen. LEFT/RIGHT CONVEYOR Select Yes to control material application from the left and right side of the truck at the Operate screen. Spinner direction can be left, right, or both can be on at the same time. The active position of the conveyor is displayed on the Operate screen. 84 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL GATE HEIGHT CONTROL Select Yes to control raising and lowering the gate height from the cab. INC/DEC PWM The PWM percentage entered determines the PWM signal level that is sent to the electric actuated cylinder when the gate increase or decrease button is pressed from the main Flex4 terminal Operate screen. The higher the PWM signal is set, the faster the gate opens or closes. INC/DEC TIME The time entered determines how long the PWM signal is sent to the electric actuated signal each time the gate increase or decrease button is pressed from the Flex4 terminal Operate screen. The higher the time is set, the longer the gate continues to open or close upon a single press of the gate increase/decrease button. Example: PWM percentage set at 40 and time set at 2 seconds. Pressing the Gate Increase button sends a 40% PWM signal to the electric actuated cylinder for 2 seconds. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 85 OPERATOR’S MANUAL DATA LOGGING (F12) The Data Logging menu screen includes those items that are stored to data files for transfer to a reporting software. To view Data Logging Screens: 1. Press F12 to display the Data Logging menu screen. 2. Press the respective item number to open a menu item. Figure 80 Data Logging Screen ALARM HISTORY Various alarm conditions can occur whenever the system encounters an abnormal condition or detects a specific alarm. Alarms are presented in either a full screen display or as an audible alarm. Full screen alarms provide an alarm description and may give instructions on how to resolve the issue. Each alarm type has an associated alarm number that can be cross-referenced in the Troubleshooting and Alarms section. Some alarms require a specific action before the alarm condition will cease. In these cases, instructions are indicated on the alarm display. Alarms can be acknowledged by pressing the Alarm Cancel button. To view Alarm History: 1. At the Data Logging screen, press 1 to access the Alarm History screen. – The number of the alarm, data, time the condition occurred, along with the alarm description displays. – Up to 275 alarms can be recalled. – Each alarm occurrence can have up to 6 occurrences of the alarm tagged with a date and time stamp. 86 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL NOTE: Press the Page Up or Page Down buttons to view screen 2 alarms. Figure 81 Alarm History Screen TRUCK ID An identifying name for a truck which can be changed at anytime. A Truck ID is used as part of the file name during import/export of configuration and data downloading to correlate the truck with the appropriate data files. 1. At the Data Logging screen, press 2 to access the Truck ID screen and enter desired ID. Figure 82 Truck ID Screen Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 87 OPERATOR’S MANUAL DRIVER SETUP Driver logins require a passcode to perform certain system functions. 1. Driver ID Configuration (tracking of routes/roads/driver) 2. Configuration Setup (entry of configuration settings) To customize Driver Details: 1. At the Data Logging screen, press 3 to display the Driver Details screen. 2. At the Driver Details screen, press the corresponding number to display the desired configuration screen. Figure 83 Driver Details Screen DRIVER ID CONFIGURATION A driver login and passcode can be enabled to require each driver to login and logout when the unit is powered on or when users change so that tracking of routes and roads with materials spread, miles driven, and route spread can be recorded for an individual driver. The default language is English but a specific language can be chosen so that during logon the system automatically changes to the user-defined language for the driver. Up to 20 different driver names and passcodes can be entered. An additional screen to add names and passcodes is selected by pressing the More button. To enable a Driver Passcode: 1. At the Driver Details screen, press 1 to display the Driver ID Configuration screen. 2. Highlight the Driver Name input box and type in a user name. 3. At the passcode input box, enter a passcode for each user. To ensure that individual driver’s data is recorded separately a different passcode should be used for each driver name. 88 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL 4. Select the appropriate language, if available. – To remove a driver’s name and passcode, highlight the corresponding delete input box located next to the user. – Use the + or - key to enter a checkmark to select. Upon exit of this screen, the selected driver and passcode will be removed. Figure 84 Driver ID Configuration and Login Screen After Driver ID Configuration is setup, the Driver Login/Logout screen appears requiring the driver’s personal passcode before gaining access to the Operate screen. Refer to the Operation section for additional information. Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 89 OPERATOR’S MANUAL CONFIGURATION SETUP NOTE: A keyboard is required to enter configuration setup screens. Enabling the Configuration Passcode will require a user to enter a passcode independent of the driver ID passcode to enter, view, or change any of the Configuration Setup screens. Setting a passcode at the Configuration Setup screen restricts system settings to only be changed by authorized users with the created passcode. Once a passcode is enabled, it must be entered to gain entry into the configuration screens. NOTE: The unit is shipped with driver and system passcode settings disabled. To modify Configuration Setup: NOTE: Passcodes can only be entered as numbers not as alpha characters or symbols. Figure 85 1. At the Driver Details screen, press 2 to display the Configuration Setup screen. 2. Highlight the Configuration Passcode input box and select Enabled. 3. At the Passcode input box, enter a passcode using numbers only. A passcode can be entered at this screen or by an attached keyboard. 4. Retype the passcode again in the Confirm Passcode input box. 5. At the Driver Login Required input box, select YES to require a driver to enter a driver passcode as well as the system configuration passcode. Select NO if a driver login personal passcode is not required and only the configuration passcode is desired. Configuration Setup and Configuration Passcode Screens 1 2 3 4 7 ENTER CONFIGURATION DATA PASSCODE IMPORT DONE 8 9 0 5 6 YOU MUST REBOOT THE TERMINAL TO SAVE ALL IMPORTED DATA ENTER REBOOT TERMINAL BACK After a configuration passcode is created, the Configuration Passcode screen appears to gain entry into any configuration setup screens. Returning to the Operate screen completes that setup session and will require re-entry of the passcode again to enter setup screens. Disabling the passcode setting will reset the system allowing full access to configuration screens. 90 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL ROUTE CONFIGURATION Twenty (20) pre-defined route names can be entered for selection on the Operate screen so that data specific to that route; rates, material, total quantity, miles driven,etc., is logged and recorded. Route specific data can also be viewed at the Operational Totals screen. To enter Route Names: 1. At the Data Logging screen, press 4 to access the Route Configuration screen. 2. Highlight the Route Name input box and type in the desired name. A maximum of 12 digits is accepted. – To remove a route name, highlight the corresponding delete input box located next to the user. Use the + or - key to enter a checkmark to select. Upon exit of this screen, the selected route will be removed. After Routes are setup, a Route button is enabled at the Operate screen to access the Route Selection screen. Refer to the Operation section for additional information. Figure 86 Route Configuration and Selection Screens Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 91 OPERATOR’S MANUAL OPERATIONAL TOTALS Granular and liquid totals are logged individually and viewable on the Totals screen by: • • • Current run totals Season totals Route To view Operational Totals: 1. At the (F12) Data Logging screen, press 5 to access the Operational Totals menu screen. 2. At the Reset Totals Enable selection, select Yes for operator access to clear totals from the Operate screen. Select No for no operator access to clear totals. The Trip Log on the Totals screen can be cleared with a Yes or No selection. 3. Select the corresponding number key to view granular, liquid, anti-ice, prewet, or active material totals. Active Materials screen displays and clears only the current materials displayed on the Operate screen. 4. At the Material menu screen, select the corresponding number key to view material totals. 5. At the Totals screen, press C to clear current totals and S to clear season totals. Material totals are reported in tons, miles, and hours for current and season totals for the following modes: AUTOMATIC MODE- total miles driven is logged in miles (km), tons (metric/ English), and gallons (liters) for each control channel and product spread. BLAST MODE- total miles driven in Blast mode is logged in miles (km), tons (metric/English) and gallons (liters) spread for each product. PAUSE MODE- total miles driven in Pause mode is logged in miles (km), tons (metric/English), and gallons (liters) spread for each product. 92 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL Figure 87 Operational Totals Screen Flex4 Control System 11001-1576-201103 SYSTEM PROGRAMMING / 93 OPERATOR’S MANUAL LIFETIME TOTALS Accumulated totals are displayed in miles and hours for Automatic, Blast, and Pause modes. These totals are informational only and cannot be changed or cleared. To view Lifetime Totals: 1. At the (F12) Data Logging screen, press 6 on the keyboard to access the Lifetime Totals screen. Figure 88 Lifetime Totals Screen 94 / SYSTEM PROGRAMMING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL CALIBRATIONS Spreader trucks have a variety of material delivery systems and various combinations of hydraulic/liquid pumps, valves, and motors. It is important that calibrations of the system and control channels are performed to define configuration characteristics and ensure optimum performance. Two calibration types are recommended prior to operation: 1. Material and Spinner System Response Calibrations 2. Drop Test Calibration IMPORTANT: Performing the following procedures in the order outlined ensures the greatest accuracy. MATERIAL AND SPINNER SYSTEM RESPONSE CALIBRATIONS (F6) A system response calibration adjusts the response time of the system to the installed hydraulic and mechanical systems. Performing this calibration determines the system response and related constants, such as Valve Boost, PWM Offset, and AFILT, for each of the control channels. Constants may vary slightly each time a system response calibration is performed. Manual fine tuning for optimum performance is acceptable. IMPORTANT: During calibrations, the truck must be running and the RPM’s should be within the truck’s normal operating range. GRANULAR RESPONSE CALIBRATION During calibration, a set of values for System Response, Valve Boost, PWM Offset, and AFILT automatically calculate, store, and display on the Granular Configuration screens for all granular materials. NOTE: Liquid pre-wet and liquid anti-ice channel setup follows same steps as granular. Refer to page 94 for Drop Test and Calibration procedures. Flex4 Control System 11001-1576-201103 To perform a Granular System Response Calibration: 1. At the System Calibration screen (F6), select (1) Granular System Response. A warning screen indicates this test activates the channel and material will dispense. 2. Press “R” to begin test. A series of steps display on the screen during calculations. When finished, the System Response Done screen displays. 3. When the calibration is complete the results automatically record in the proper locations. Press “C” to automatically begin drop test or press “D” to return to the Calibration screen. CALIBRATIONS / 95 OPERATOR’S MANUAL Figure 89 System Response Calibration Screens NOTE: Liquid pre-wet and anti-ice channels have similar calibration steps as granular. 96 / CALIBRATIONS RECORDING CALIBRATION DATA After performing each calibration, record the calibration constants on the Calibration Data Record sheets included with this manual. If console replacement is necessary, export system files to a USB memory device for import to another system. Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL MAINTAINING CALIBRATION ACCURACY Calibration accuracy can be affected by various conditions and to retain optimum performance a system calibration should be performed for the following conditions: • • • • • • If a new material is added and the spreader, nozzle, or flow meter constant is not accurately known, perform a granular or liquid calibration routine. If wear of the conveyor/auger mechanism, actuator valves, flow meter, nozzles, or other system components is suspected, perform a new catch test (granular or liquid calibration) to re-establish APR accuracy. Perform a ground speed calibration after installing new or different tires. Each known physical (mechanical) change in the system should be followed immediately by a System Response calibration on the related control channel (granular, liquid pre-wet, liquid anti-ice, or spinner). A periodic system recalibration when repair or replacement has occurred on any system components, including hydraulic hoses, fluid changes, and normal wear. A yearly system calibration of all control channels at the beginning of each spreader season. SYSTEM RESPONSE ADJUSTMENTS Adjustments after a system calibration can be made so the system responds faster or slower than calculated by the automatic calibration routines. Automatic calibration routines should always be performed prior to modification to establish basic values. System performance can be improved by adjusting the following functions: SYSTEM RESPONSE CONSTANT • • Control system responds slowly in speed and is slow to start – Increase the system response value System oscillates around the target APR – Decrease the system response value Excessive oscillation should be limited to +/-5% of the target APR to minimize wear on the PWM valve. Most systems can be tuned by altering only this value. VALVE BOOST Valve Boost increases system response only at startup to quickly start system spreading. The value does not affect stability when operating at the target APR and does not normally require adjustment. Flex4 Control System 11001-1576-201103 CALIBRATIONS / 97 OPERATOR’S MANUAL AFILT Noisy feedback sensors cause the APR’s to randomly jump. AFILT value indicates the amount of feedback noise rejection. The smaller the number, the greater the filtering. Decreasing the AFILT can reduce the problem but also can cause the system to become more sluggish. Typically this value does not require adjustment. GRANULAR DROP TEST CALIBRATION The Drop Test determines the spreader constant for a given granular material. The spreader constant is the number of pulses generated by the application rate sensor per pound of granular material discharged. A separate calibration routine must be run for each granular material used. During a calibration the control system runs the conveyor/auger mechanism dispensing material while the vehicle is stationary. When a sufficient amount of material has been discharged, the operator stops the spreader mechanism, weighs the material discharged, and enters the amount at the Calibration screen. The system then calculates, stores, and displays the Spreader Constant. DROP TEST PREPARATION 1. Load the vehicle hopper with the desired material and verify the gate height is adjusted to the proper setting on the V-Box spreader. If tailgate spreads are in use, ensure auger is full. 2. Load enough material to provide a uniform flow throughout the calibration procedure. 3. Position a suitable container or drop cloth to catch all dispensed material from the conveyor/auger. The container must be large enough to obtain a good, representative sample. The larger the sample weighed, the better the accuracy. Alternatively, if a vehicle scale is available, weigh the truck before and after dispensing material. 4. System is ready for calibration drop test. PERFORMING A GRANULAR DROP TEST NOTE: Steps 1 and 2 are performed when a granular drop test is initiated from the F6 Calibration screen. 1. At the System Calibration screen (F6), select the Granular Drop Test and follow the onscreen instructions. 2. At the Granular Calibration screen, select and press the corresponding number (1-4) of the appropriate material. A warning message indicates material will dispense when the procedure is started. Ensure all personnel are clear before starting the next step. IMPORTANT: If a gate height sensor is installed, verify the gate height sensor selection is enabled at the (F) Accessory Sensor screen before performing the drop test. 98 / CALIBRATIONS Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL NOTE: Calibration Data Sheets are available in back of this manual to record constants. Flex4 Control System 11001-1576-201103 3. With the vehicle stationary, engage the hydraulic system. 4. Increase engine RPMs to normal operating range. 5. Press “R” to begin test and to run the conveyor/auger. Several steps display during calculations before the System Response Done screen appears. The number in the middle of the screen shows the counts accumulating from the APR sensor. If a count is not recorded and stays on “0”, stop the test and check the application rate sensor. 6. When a sufficient amount of material has dispensed, press “S” to stop the system. A screen appears indicating the previous spreader constant and the sensor counts accumulated during the current run. 7. Perform the next step while the screen waits for the results. 8. If using a vehicle scale, reweigh the truck and calculate the amount of material dispensed in pounds. 9. Enter that number into the console and press “D” when finished. The new spreader constant is now stored and displayed on the calibration screen and on the appropriate configuration screen for this material. 10. For maximum accuracy, repeat the entire procedure at least three times. 11. Average the results and enter the average as the final spreader constant. 12. Record the material’s spreader constants on the Calibration Data Records sheets at the rear of this manual. 13. Repeat this procedure for each granular material used. CALIBRATIONS / 99 OPERATOR’S MANUAL Figure 90 Granular Drop Test Procedure 100 / CALIBRATIONS Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL NOTE: Pressing “S” stops the calibration and values default to the original settings. GRANULAR CALIBRATION ADJUSTMENTS If small but consistent application rate errors are observed over a period of time, the spreader constant can be modified to improve application accuracy. Refer to Appendix A for steps to re-calculate a new spreader constant. This constant can be manually entered on the Granular Configuration screen. A granular calibration routine can also be repeated to correct this type of APR error. LIQUID DROP TEST CALIBRATION (F6) A Liquid Drop Test Calibration determines a flow meter constant (K Factor) for each liquid material used. The K Factor represents the number of pulses generated by the flow meter per gallon of liquid dispensed. The nozzle constant is a measure of flow rate through the nozzle at a standard pressure. Separate calibrations are necessary for each liquid material because of viscosity differences. The liquid drop test routine causes the control system to run the liquid pump dispensing material while the vehicle is stationary. When a sufficient amount of liquid has been discharged, the system is stopped and the discharged liquid weighed, and the amount entered at the Calibration screen. The system then calculates, stores, and displays the K Factor. DROP TEST PREPARATION 1. Load vehicle tank with material. 2. Position a suitable container to catch all the material dispensed through the liquid pump. The container must be large enough to obtain a good, representative sample. The larger the sample weighed, the higher degree of accuracy. When calibrating a pre-wet liquid material, the pre-wet bar can be removed from its mounting and placed inside the catch container. Alternatively, especially for flow meter and anti-ice liquid materials, temporarily disconnect an appropriate hose and place inside the catch container. 3. System is ready for calibration drop test. NOTE: Calibration Data Sheets are available in back of this manual to record constants. A warning message indicates material will dispense when procedure is started. Ensure all personnel are clear before starting the next step. PERFORMING A LIQUID DROP TEST NOTE: Steps 1 and 2 are performed when a granular drop test is initiated from the F6 Calibration screen. Flex4 Control System 11001-1576-201103 1. At the System Calibration screen (F6), select the Liquid Drop Test and follow the onscreen instructions. 2. At the Liquid Calibration screen, select and press the corresponding number (1-4) of the appropriate material. – For pressure-based anti-ice systems, a target pressure must be entered. This should be the nozzle manufacturer’s rating pressure typically 40 psi (2.75 bar). – If running pressure, ensure booms are drained prior to running Offset CALIBRATIONS / 101 OPERATOR’S MANUAL A warning message displays indicating that material will dispense when channel is activated. Ensure all personnel are clear before starting the next step. 3. When ONLY the liquid channel is propelled by the hydraulic system, start the engine keeping the vehicle stationary. 4. Engage the hydraulic system and increase the engine RPMs to normal operating range. 5. Press “R” to run the liquid pump and start the calibration routine. For flow meter based systems, use the Rate Increase/Decrease buttons on the switch module to obtain an adequate discharge rate. The number displayed indicates the accumulating count from the APR sensor. 6. When a sufficient amount of liquid has dispensed, press “S” to stop. – For a flow meter based system, a screen appears showing the previous K Factor and the sensor counts accumulated during the current run. – For a pressure-based system, the previous nozzle constant and collection time display. The screen asks for an entry of gallons before proceeding. 7. Perform the next step while the screen waits for the results. 8. Weigh the material caught and calculate the amount dispensed in gallons. 9. Enter the number into the console and press Enter. IMPORTANT: The amount dispensed value must be entered to adjust the K Factor value; otherwise the K Factor will remain at the current setting. 10. Press “D” when finished. The flow meter constant is now stored and displayed on this screen and on the Liquid Configuration screen for this material. 11. For maximum accuracy, repeat the entire procedure at least three times. 12. Average the results and enter the average as the final K Factor constant. 13. Record the material’s K Factor constants on the Calibration Data Records sheets at the rear of this manual. 14. Repeat this procedure for each liquid material used. 102 / CALIBRATIONS Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL Figure 91 Liquid Drop Test Calibration Procedure LIQUID CALIBRATION ADJUSTMENTS If small but consistent application rate errors are observed, the values can be manually adjusted to improve application accuracy. Refer to Appendix A for steps to re-calculate a new flow meter constant. This constant can be manually entered on the Liquid Configuration screen. A liquid calibration routine can also be repeated to correct this type of APR error. Flex4 Control System 11001-1576-201103 CALIBRATIONS / 103 OPERATOR’S MANUAL AUXILIARY SYSTEM RESPONSE AND DROP TEST An additional channel is available for granular or liquid rate control. Channel Setup screens require the same configuration parameters, calibration, and drop test requirements as channels 1 and 2. Refer to the Granular and Liquid Configuration sections for additional information. SPINNER SYSTEM RESPONSE CALIBRATION Performing a Spinner System Response determines PWM Offset and PWM Saturation values when using a proportional valve with no feedback sensor to drive the spinner channel. Spinner calibration allows for open loop or closed loop operation of the spinner to coordinate spread width knob position with a specific spread width for lane mile material application. To perform a Spinner System Response Test: 1. At the System Calibration screen (F6), select Spinner System Response and follow the onscreen instructions. 2. At the Spinner System Response screen, press “R” to begin test. 3. Spinner will be set to off when the calibration starts. Slowly rotate the knob clockwise until the minimum spinner speed is achieved. 4. Press R to run. 5. When the desired offset is achieved, press C to capture the offset. 6. Rotate the spinner knob clockwise until the maximum spinner speed is achieved. 7. Press C to capture the saturation. 8. Spinner calibration is complete. Press D to exit. 9. libration drop test. NOTE: Calibration Data Sheets are available in back of this manual to record constants. 104 / CALIBRATIONS A warning message indicates material will dispense when procedure is started. Ensure all personnel are clear before starting the next step. Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL Figure 92 Spinner System Response Screens Flex4 Control System 11001-1576-201103 CALIBRATIONS / 105 OPERATOR’S MANUAL SPINNER SPREAD WIDTH A spinner spread width calibration adjusts to the spinner configuration settings defined at the Spinner Calibration screen and correlates these settings to the increase and decrease adjustment of the spread width knob automatically adjusting the amount of material applied. A spread width bar graph displays on the Operate screen to indicate spread width percentage. IMPORTANT: A spinner spread width calibration can only be performed when spinner units are selected as feet on the Spinner Configuration (F4) screen. To perform a Spinner System Response Calibration: 1. Load vehicle with material. 2. At the F6 Calibration menu, select Spinner Spread Width and follow onscreen instructions. 3. Position a suitable container to catch all granular material dispensed from the conveyor/auger. The larger the sample weighed, the better the accuracy. The container must be large enough to obtain a good representative sample. 4. Press C to proceed to further calibration instruction. 5. Press S to to start calibration. Figure 93 Spinner Spread Width 6. When a sufficient amount of material has dispensed, press “C” to pause the calibration. 7. Measure the material dispensed and enter the spread width amount in inches into the Spread Width popup window. This process is required 106 / CALIBRATIONS Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL an additional 4 times to calculate an average that appears on the screen each time another calibration is ran. 8. After the final calibration, a calibration complete screen appears. Press “D” to return to the main Calibration screen. Figure 94 Spinner Spread Width Enter measured spread width into popup window Flex4 Control System 11001-1576-201103 CALIBRATIONS / 107 OPERATOR’S MANUAL GROUND SPEED CONFIGURATION (F8) Ground speed configuration sets the parameters for ground speed type and performs a calibration. Figure 95 Ground Speed Configuration GROUND SPEED SOURCE CAN Used when ground speed is provided by a radar/digital (3-wire) type sensor connected to the cab harness or if radar/forward ground speed is communicated on the CAN bus. DIGITAL Used when ground speed is provided by a radar/digital (3-wire) type sensor connected to the actuator harness. RELUCTANCE Used when ground speed is provided by a reluctance (2-wire) type sensor connected to the actuator harness through an adapter harness. MAXIMUM CONTROL SPEED Indicates the allowed maximum speed in AUTO mode before a Maximum Speed Exceeded warning occurs. The value entered is based on the highest speed for acceptable system performance. If a zero is entered, the function is disabled. MANUAL SPEED ON Manual Speed On overrides the current system when the ground speed sensor is not operating properly. An internally-generated ground speed signal allows for continued operation and can also be used for testing, troubleshooting, or calibrating the vehicle while stationary. MANUAL SPEED ACCESS Allows the operator to activate the manual speed mode when necessary. Manual speed can be enabled and disabled at the Material Selection screen. 108 / CALIBRATIONS Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL MAXIMUM MANUAL SPEED Sets the maximum manual ground speed allowed to spread the target APR. MANUAL SPEED Represents the ground speed in miles per hour with an artificial, internally-generated signal. Vehicle speed should run close to the maximum manual speed to ensure materials are spread to the target APR. CONTROL STARTUP SPEED The speed the system begins to operate when ground speed sensor pulses start. Until this threshold is crossed, the startup ground speed signal is used. CONTROL SHUTOFF SPEED Minimum ground speed allowed before the system stops operation. It is recommended that shutoff speed be set at 0.0 unless speed appears from a mechanical sensor. GROUND SPEED CONSTANT Determines the number of pulses received from the ground speed sensor per mile of travel. If unknown, the value automatically calculates during a ground speed calibration. Flex4 Control System 11001-1576-201103 CALIBRATIONS / 109 OPERATOR’S MANUAL GROUND SPEED CALIBRATION (F8) Ground speed calibration establishes a ground speed constant(s) for the vehicle. The constant is determined by counting the number of ground speed sensor pulses generated in a distance of one mile. Figure 96 Ground Speed Calibration Screens 110 / CALIBRATIONS Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL To establish a Ground Speed Constant: 1. Accurately measure one mile marking the start and finish points. Markers should be visible from the cab while driving past. Alternatively, two highway mileage markers can be used. 2. At the Ground Speed Calibration screen (F8), press C to begin calibration. 3. Drive to the start of the course at a minimum speed of 5 mph (8Km/hr). 4. When even with the start marker, press S on the keyboard. The calibration begins as the vehicle is moving. 5. Drive at normal operating speed. NOTE: For better accuracy, it is recommended to slow down at the second marker so reaction time is better when pressing “S” to stop. Flex4 Control System 11001-1576-201103 6. At the finish marker, press C to complete the calibration. 7. Press S to save the value, press R to restart the calibration or press Esc to abort the calibration. 8. To ensure accuracy, repeat the calibration procedure three times and average the results. Enter the average value. 9. Record the ground speed constant on the Calibration Data Records sheets at the rear of this manual. CALIBRATIONS / 111 OPERATOR’S MANUAL 112 / CALIBRATIONS Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL IMPORT/EXPORT DATA FILES Two separate functions can be performed with the Import/Export button. • • Import/export of system configuration settings to a USB memory device to import to other terminals Export of logged data files for reporting purposes PASSCODE ENABLED If a driver passcode is enabled at the Configuration Setup screen, this passcode is required before importing or exporting files can occur. The code can be entered on the Passcode screen or by using an attached keyboard. The Passcode screen appears after pressing the Import/Export button. Enter the passcode and press the Enter button to proceed. Figure 97 Passcode Screen 1 2 7 ENTER CONFIGURATION DATA PASSCODE IMPORT DONE 3 4 8 9 0 5 6 YOU MUST REBOOT THE TERMINAL TO SAVE ALL IMPORTED DATA ENTER REBOOT TERMINAL BACK NOTE: USB memory device must be inserted into the terminal before the Import/Export button appears. EXPORT CONFIGURATION AND LOG DATA FILES To export Configuration Files: 1. Insert USB memory device into side of terminal. 2. At the Operate screen, an Import/Export button appears after the USB memory device is inserted. 3. Press the Import/Export button. 4. At the Import Export screen, select Config USB Export button. The Export to USB confirmation screen displays the file name that will contain the configuration files. 5. Press the Export Now button. A Data Export Done screen indicates file transfer is complete. EXPORT FILE STRUCTURE To export Log Data Files: Log data files are exported following the same procedure as exporting configuration files (select Data USB Export button). Log data files can be imported to a reporting software tool to create truck fleet reports. Flex4 Control System 11001-1576-201103 IMPORT/EXPORT DATA FILES / 113 OPERATOR’S MANUAL The export file structure when exporting configuration and log data files to a USB memory device is formatted as follows: • • A folder is created that Flex4 data is stored (Flex4_DataFolder) Each time an export occurs the file name is saved with the Flex4 name identifier, the Truck ID, date of the download, and time of the download FILE STRUCTURE: Flex4_DataFolder/Flex4_TruckID_Date_Time EXAMPLE: Flex4_DataFolder/Flex4_42067_2011-09-14_15-00-39 Figure 98 Exporting Configuration Files IMPORT/EXPORT CONFIG USB IMPORT CONFIG USB EXPORT DATA USB EXPORT CONFIGURATION LOGGED DATA BACK EXPORT TO USB CONFIGURATION FILE NAME: Dj_Flex4_Settings_42067.xml Logged Data Files Export in Progress EXPORT NOW BACK DATA EXPORT DONE BACK 114 / IMPORT/EXPORT DATA FILES Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL IMPORT CONFIGURATION FILES To import Configuration Files: 1. Insert USB memory device into side of terminal. 2. At the Operate screen an Import/Export button appears after the USB memory device is inserted. 3. At the Import/Export screen, select Config USB Import button. This button only appears if files exist on the USB memory device. 4. Select the desired file to import and press the Import File button. 5. Select the desired file types to import and press the Import Now button. Use the terminal keys to select the choices. – A Data Import screen indicates file(s) are uploaded to terminal. Figure 99 Importing Configuration Files IMPORT/EXPORT CONFIG USB IMPORT CONFIG USB EXPORT DATA USB EXPORT CONFIGURATION LOGGED DATA BACK IMPORT FROM USB SELECT FILE FROM BELOW LIST Dj_Flex4_Settings_42067.xml IMPORT FILE BACK IMPORT SETTINGS SELECT DATA TO BE IMPORTED CONFIGURATIONS ROUTE NAMES DRIVER NAMES PASSCODES USE TERMINAL KEYS TO SELECT DATA Flex4 Control System 11001-1576-201103 IMPORT now BACK IMPORT/EXPORT DATA FILES / 115 OPERATOR’S MANUAL 6. Press the Reboot Terminal button to turn the system off and on again to accept imported data. Figure 100 Reboot Terminal DATA IMPORT DONE YOU MUST REBOOT THE TERMINAL TO SAVE ALL IMPORTED DATA REBOOT TERMINAL BACK 116 / IMPORT/EXPORT DATA FILES Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL DIAGNOSTICS Diagnostic screens (F7) can be used to check system performance by displaying sensor input readings that connect to the terminal, control module, and output module that could indicate potential issues. Three Diagnostic screens are available and selected based on where the sensor is connected: • • • Terminal (joystick inputs) Control module (control channels, spinner, auxiliary sensors) Output module (added accessories) PERFORM A DIAGNOSTICS CHECK To perform a diagnostics check, vehicle ground speed must be zero and manual ground speed must be enabled at the appropriate ground speed setting. Actual readings will display on the Diagnostics screen at the defined rate and the manual ground speed entered when the switch module Auto On button is enabled. Enable Manual Ground Speed: 1. Enable manual ground speed with the vehicle stopped and the switch module Auto On/Off button in Off mode. 2. At the Operate screen, press the Material Select button to display the Material Selection screen. 3. Press the Manual Speed button to select Enable Manual Speed. 4. Press the Select button to enter the appropriate ground speed to perform test. 5. Press the Back button to return to the Operate screen. Verify that the manual speed is active on the screen. 6. Connect the keyboard to access the Diagnostics screen and press the F7 button on the keyboard to display the Diagnostics screen. Flex4 Control System 11001-1576-201103 DIAGNOSTICS / 117 OPERATOR’S MANUAL Figure 101 Enable Manual Ground Speed O.O O.O Increase/ decrease manual speed To Perform a Diagnostics Check: 1. Press the appropriate number on the keyboard to select the terminal, control module, or output module screens. 2. At the selected Diagnostics screen, press the switch module Auto On/ Off button to On to display system readings. Figure 102 Main Diagnostic Screen 118 / DIAGNOSTICS Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL TERMINAL The Terminal screen indicates the current state of the joystick inputs connected to the terminal as either ON or OFF. Pressing the appropriate joystick function while on this screen indicates if the joystick is functioning properly. – An incorrect state on the screen that doesn’t correspond with the actual joystick function could indicate the joystick is not wired correctly or a defective joystick. Figure 103 Terminal Diagnostics Screen CONTROL MODULE The Control Module Diagnostics screen provides sensor readings for control channels, auxiliary channel, spinner, and accessory sensors. Any misreadings could indicate a control module problem, a faulty sensor, or bad sensor connection. 1. At the Main Diagnostics screen, press 2 on the keyboard to display the Control Module Diagnostics screen. 2. Select the appropriate material (granular, liquid, auxiliary), spinner, or accessory sensor to perform the relevant diagnostic check. Figure 104 Control Module Diagnostics Screen Flex4 Control System 11001-1576-201103 DIAGNOSTICS / 119 OPERATOR’S MANUAL MATERIAL Target Rate Target Rate displays the defined application rate set at the configuration screen and the rate the Diagnostics screen will perform the test. – Target rate can be adjusted at the Operate screen by pressing the Increase/Decrease Rate buttons on the switch module to achieve the desired target rate. Actual Rate Actual rate is the rate that is being applied during the test. The Actual Rate should match or run closely to the Target Rate. – A wrong actual rate could indicate that a system response should be performed or a faulty feedback sensor. Set Point Set Point, displayed in hertz, is the pulses per second required for the feedback sensor to achieve the target rate at the manual ground speed set. – No set point could indicate a configuration issue or faulty master module. Filtered Feedback Filtered Feedback is the actual pulses per second of the feedback sensor and indicates the PWM signal being sent to the hydraulic control valve. – No filtered feedback could indicate a faulty feedback sensor. Pulse Count Pulse Count reading indicates pulses sent from the feedback sensor to the rate control module. Output PWM Output PWM indicates the current PWM signal and continues to increase until the desired target rate is reached and then should remain steady when achieved. RPM RPM indicates the revolutions per minute of the conveyor/auger. Ground Speed Frequency Ground Speed Frequency identifies the pulses per second coming into the control module and could indicate a potential problem with the module, not reading a signal from the sensor, or a speed sensor failure. Voltage readings from the truck battery are displayed for the following: – – – – 120 / DIAGNOSTICS Solenoid Power Solenoid Ground ECU Power ECU Ground Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL SPINNER The Spinner Diagnostics screen provides readings related to the rotary spinner knob on the operator switch module and corresponding PWM signal being sent to the coil controlling oil flow to the spinner motor. Any misreadings could indicate a faulty switch module or rate control module. Figure 105 Spinner Diagnostics Target Rate Only applicable if spinner is set for RPM control or GSRS mode. Output PWM Output PWM indicates the current PWM signal and continues to increase until the desired target rate is reached and then should remain steady when achieved. Ground Speed Frequency Ground Speed Frequency identifies the pulses per second coming into the control module and could indicate a potential problem with the module, not reading a signal from the sensor, or a speed sensor failure. Voltage Readings Voltage readings from the truck battery are displayed for the following: – – – – Flex4 Control System 11001-1576-201103 Solenoid Power (voltage from battery to solenoid relays) Solenoid Ground (voltage from battery to solenoid relays) ECU Power (voltage present at rate controller module) ECU Ground (voltage present at rate controller module) DIAGNOSTICS / 121 OPERATOR’S MANUAL Accessory Sensors Voltage readings of accessory sensors relate to voltage feedback from specific sensors in their current position. When sensor position changes, the voltage reading changes. – A zero (0) voltage reading indicates a faulty sensor or bad connection. Ground Speed Frequency Ground Speed Frequency identifies the pulses per second coming into the control module and could indicate a potential problem with the module, not reading a signal from the sensor, or a speed sensor failure. Voltage Readings Voltage readings from the truck battery are displayed for the following: – – – – Solenoid Power (voltage from battery to solenoid relays) Solenoid Ground (voltage from battery to solenoid relays) ECU Power (voltage present at rate controller module) ECU Ground (voltage present at rate controller module) Figure 106 Accessory Sensor Diagnostics 122 / DIAGNOSTICS Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL OUTPUT MODULE Output Module Diagnostics screen indicates the current state of attached accessories such as boom section shutoff valves, V-Box gate, front/rear conveyor valves, left/right discharge cross conveyors valves, and the accessory 12 volt switched output. Press the appropriate Accessory button to verify correct position. An incorrect state on the screen that doesn’t correspond with the actual function could indicate the Figure 107 Output Module Diagnostics Screen Accessory Buttons Flex4 Control System 11001-1576-201103 DIAGNOSTICS / 123 OPERATOR’S MANUAL 124 / DIAGNOSTICS Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL TROUBLESHOOTING Error messages display when an abnormal event occurs. For any failure that persists, contact DICKEY-john Technical Support at 1-800-637-3302. Flex4 Control System 11001-1576-201103 TROUBLESHOOTING / 125 OPERATOR’S MANUAL ERROR CODE ERROR PROBABLE CAUSE CORRECTIVE ACTION 10 Rate Controller Stack Alarm Internal system software error. Cycle system power off and on. 11 Rate Controller System Stack Alarm Internal system software error. Cycle system power off and on. 50 Rate Controller Offline Alarm Communication to the rate controller has been lost. 1. Verify rate control module has a good connection. 2. Inspect CAN harness for damage. 3. Inspect ECU harness and fuse for damage. 4. Inspect ECU for damage. 51 Rate Controller Intermittent Alarm Communication to the rate controller was lost but has been re-established. Check for intermittent connections. 1. Verify rate control module has a good connection. 2. Inspect CAN harness for damage. 3. Inspect ECU harness and fuse for damage. 4. Inspect ECU for damage. 52 Remote Operator Controller Offline Alarm Communication to the switch module has been lost. 1. Verify switch module is connected properly. 2. Inspect CAN harness for damage. 3. Inspect ECU harness and fuse for damage. 4. Inspect ECU for damage 53 Output Module Offline Alarm Output member module is no longer online. 1. Verify output module is connected properly. 2. Inspect CAN harness for damage. 3. Inspect ECU harness and fuse for damage. 4. Inspect ECU for damage 54 Output Module Intermittent Alarm Communication to the output module was lost but has been re-established. Verify output module is connected properly. 2. Inspect CAN harness for damage. 3. Inspect ECU harness and fuse for damage. 4. Inspect ECU for damage 200 Auto has been turned off alarm Master switch was left on (auto) and is now in a state that does not allow the system to run. Turn Auto off before entering setup mode with keyboard. Check connections to feedback sensors. 222 Valve Calibration Abort Alarm Control channel valve calibration has been aborted due to an error. Try calibration again. 201 Set Point Alarm A negative setpoint has been calculated which is not a normal occurrence causing an error. Check channel parameters and perform the appropriate material valve calibration (liquid, granular or auxiliary) at the F6 calibration screen. 206 In Manual Alarm A manual override state occurs when an application rate sensor or flow meter fails. Manual override allows material to be spread at the same programmed rate without interruption. When a failure occurs, the rate decreases to “0” and “Manual” replaces the material name. Rate returns from “0” back to target rate while manual override is enabled. Material may be over or under applied in this mode. Check feedback sensors, i.e., application rate sensors and flow meters. 208 Application Rate error (granular) A fully open valve is indicated but the target APR cannot be achieved. 1. Reduce the truck ground speed to allow the system to catch up and the error to clear. 2. Shift to a lower gear to increase engine RPM and hydraulic pump rotation. 3. Check hydraulic disconnects and filter. 4. Ensure correct spreader constant is programmed into console. Check original setting or run a granular calibration. 5. Incorrect PWM SAT setting (See Granular Configuration screen). Compare against original setting or run system response on the granular channel setting. 6. Check for insufficient hydraulic oil flow at normal engine RPM. 7. Check spreader valve, electrical connections to the valve coil, resistance of the coils (See manufacturers specifications), and verify voltage from control console. 126 / TROUBLESHOOTING Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL ERROR CODE 208 ERROR Application Rate Error (liquid) PROBABLE CAUSE A fully open valve is indicated but the target APR cannot be achieved. CORRECTIVE ACTION 1. Check to see if the liquid tanks are low, shutoff valves are partially closed, bypass valves are open too far, or an obstruction is in the liquid tank outlet. 2. Check filters between the liquid tank and suction side of the liquid pump for blockage. 3. Check for plugged nozzles or nozzles that are too small to supply sufficient gallons per minute. 4. If using a electric liquid pump, check that the nozzle pressure (spray bar pressure) does not exceed 40 psi. Some electric pumps have an internal pressure switch to shut pump off high back pressure conditions. 5. Ensure a correct K-FACTOR is programmed. Compare it against the number stamped on the flowmeter body or recorded on the Calibration Data Record Sheet. If original settings are not available, run a liquid calibration. 6. Observe the PWM SAT under the Liquid Configuration screen. Compare against original setting. If not available, run a system response on the liquid channel. 250 Prewet Channel Disabled Prewet is not linked to a granular channel. The system cannot run as configured. 1. Setup a granular channel to use as a reference for the prewet application. 2. Or change the prewet channel type. 300 Invalid Gate Height Sensor Configuration The calibration points of the gate height are incorrect. Most likely, the values do not follow an increasing or decreasing only pattern. 1. Check calibration numbers and re-run calibration. 2. or accept default values and continue calibration. 301 Invalid Gate Height Open Calibration The open calibration point is near zero. A zero full open position is not valid. 1. Check calibration numbers and re-run calibration. 2. or accept default values and continue calibration. 302 Invalid Temperature Calibration Temperature calibration did not complete. 1. Verify temperature sensor adapter is connected and the temperature sensor is disconnected. With adapter connected and sensor unplugged, the signal should toggle between 0.7V and 2.7V. 400 GPS Signal Low Poor GPS signal 1. Verify GPS is enabled at the F10 screen. 2. GPS signal may be blocked. Move to a clear area. 3. Check that receiver connection is secure. 401 Data Memory Near Full Memory for storing operation data is running low. 1. Export data to a USB memory device. 402 Data Log Memory Full Memory for operation is full and no additional data can be saved. 1. Export data to a USB memory device. 500 Gate High Gate is above the open or highest calibrated point. 1. Check sensor and calibrations. 501 Gate Low Gate is below the closed or lowest calibrated point. 1. Check sensor and calibrations. 502 Bed Height Too High Bed is above the alarm value. 1. Lower bed or check sensor. 503 Down Pressure Too High Down pressure has exceeded the alarm threshold. 1. Reduce down pressure or check sensor. 504 TankPressureLow Tank level has dropped below alarm level. 1. Fill Tank. 2. Adjust alarm level setting. 3. Check sensor. 505 Air Temp Below Alarm Value 1 Temperature has dropped below alarm threshold. 1. Adjust alarm setting. 2. Check sensor. 506 Air Temp Below Alarm Value 2 Temperature has dropped below alarm threshold. 1. Adjust alarm setting. 2. Check sensor. 507 Air Temp Below Alarm Value 3 Temperature has dropped below alarm threshold. 1. Adjust alarm setting. 2. Check sensor. 508 Road Temp Below Alarm Value 1 Temperature has dropped below alarm threshold. 1. Adjust alarm setting. 2. Check sensor. 509 Road Temp Below Alarm Value 2 Temperature has dropped below alarm threshold. 1. Adjust alarm setting. 2. Check sensor. Flex4 Control System 11001-1576-201103 TROUBLESHOOTING / 127 OPERATOR’S MANUAL ERROR CODE ERROR PROBABLE CAUSE 510 Road Temp Below Alarm Value 3 511 Digital Accessory 1 Active 512 Digital Accessory 1 High Sensor has reached the defined high alarm limit value. 1. Adjust alarm setting. 2. Check sensor. 513 Digital Accessory 1 Low Sensor has reached the defined low alarm limit value. 1. Adjust alarm setting. 2. Check sensor. 514 Digital Accessory 1 Shutdown Digital accessory sensor has reached the defined alarm limit and the control has been shutdown to protect the system. 1. Adjust alarm setting. 2. Check sensor. 515 Digital Accessory High Shutdown Sensor has reached the defined high alarm shutdown limit and the control has been shutdown to protect the system. 1. Adjust alarm setting. 2. Check sensor. 516 Digital Accessory Low Shutdown Sensor has reached the defined low alarm shutdown limit and the control has been shutdown to protect the system. 1. Adjust alarm setting. 2. Check sensor. 517 Digital Accessory 2 Active 518 Digital Accessory 2 High Sensor has reached the defined high alarm limit value. 1. Adjust alarm setting. 2. Check sensor. 519 Digital Accessory 2 Low Sensor has reached the defined low alarm limit value. 1. Adjust alarm setting. 2. Check sensor. 520 Digital Accessory 2 Shutdown Digital accessory sensor has reached the defined alarm limit and the control has been shutdown to protect the system. 1. Adjust alarm setting. 2. Check sensor. 521 Digital Accessory High Shutdown Sensor has reached the defined high alarm shutdown limit and the control has been shutdown to protect the system. 1. Adjust alarm setting. 2. Check sensor. 522 Digital Accessory Low Shutdown Sensor has reached the defined low alarm shutdown limit and the control has been shutdown to protect the system. 1. Adjust alarm setting. 2. Check sensor. 523 Hopper Low Hopper level is low. 1. Fill hopper. 2. Check sensor. 604 ECU Low Voltage 1. Damaged CAN or module harness. 2. Defective module 1. Inspect CAN/module harness of the module for damage. 2. Inspect module for damage and replace, if necessary. 605 ECU High Voltage 1. Damaged CAN or module harness. 2. Defective module 1. Inspect CAN/module harness of the module for damage. 2. Inspect module for damage and replace, if necessary. 606 Solenoid Low Voltage 1. Damaged CAN or module harness. 2. Blow module harness fuse. 3. Defective module. 1. Inspect CAN/module harness of the module for damage. 2. Inspect module harness fuse and replace, if necessary. 3. Inspect module for damage and replace if necessary. 607 Solenoid Voltage with Control Shutdown Solenoid voltage is too high and the control system has shutdown. 1. Voltage issue must be corrected before control can resume. 608 Ground Low Voltage 1. Damaged/shorted actuator harness 2. Defective PWM valve driver or Servo valve driver. 3. Defective module. 1. Inspect actuator harness for damage around the PWM and Servo valve connections. Repair or replace harness. 2. Inspect PWM or Servo valve drivers for damage and replace if necessary. 3. Inspect module for damage and replace if necessary. 609 Ground High Voltage Ground offset has drifted high. 1. Check vehicle grounding. 128 / TROUBLESHOOTING Temperature has dropped below alarm threshold. CORRECTIVE ACTION 1. Adjust alarm setting. 2. Check sensor. 1. Adjust alarm setting. 2. Check sensor. 1. Adjust alarm setting. 2. Check sensor. Flex4 Control System 11001-1576-201103 OPERATOR’S MANUAL APPENDIX A CONVERTING CONSTANTS FINE TUNING APPLICATION Adjusting Granular Constants If small (less than 10%) but consistent granular APR errors (either high or low) are observed over a period of time, fine tuning of the system can be performed by adjusting the value of the spreader constant by the same percentage as follows: New SPR CON = Old SPR CON x Target APR Actual APR EXAMPLE: If SPR CON is 100 and Target APR is 300 LBS/MILE but Actual APR is known to be 315 LBS/MILE, adjust SPR CON using the above formula: New SPR CON = 100 x 300 = 95.2 315 NOTE: Keyboard enter the new SPR CON on the appropriate (Granular) configuration screen. Adjusting Liquid Constants In a manner similar to that for granular (shown above,), liquid APR errors can be corrected by fine tuning the flowmeter constant (K-FACTOR) as follows: New K-FACTOR = Old K-FACTOR x Target APR Actual APR EXAMPLE: If K-FACTOR is 1,000 and Target APR is 10 GAL/MILE, but Actual APR is known to be 9.5 GAL/MILE, adjust K-FACTOR using the above formula: New K-FACTOR = 1000 x Flex4 Control System 11001-1576-201103 10 9.5 = 1053 APPENDIX A CONVERTING OPERATOR’S MANUAL CALCULATING SPREADER CONSTANTS The spreader constant can be calculated if the following is known: A = Number of pulses per revolution of the sensor shaft. B = Turns of the sensor shaft for each turn of the final shaft. C = Pounds of material discharged per revolution of the final shaft. SPR CON = A x B Pulses Per Pound C EXAMPLE: A = 360 pulses per revolution (for Dj sensor p/n 46436-017X). B = 25 turns of the sensor shaft for each turn of the final shaft. C = 50 pounds of material discharged per revolution of final shaft. SPR CON = 360 x 25 = 180 P/LB 50 NOTES: 1. V-Box spreaders have a different SPR CON for each gate setting. 2. The number of pulses per revolution for several Dj shaft sensors are: 360 for p/n 46436-017X (standard DICKEY-john shaft sensor). 60 for p/n 10844-000X 180 for p/n 464361500S1 130 / APPENDIX A CONVERTING Flex4 Control System 11001-1576-201103 Dealers have the responsibility of calling to the attention of their customers the following warranty prior to acceptance of an order from their customer for any DICKEY-john product. DICKEY-john® WARRANTY DICKEY-john warrants to the original purchaser for use that, if any part of the product proves to be defective in material or workmanship within one year from date of original installation, and is returned to DICKEY-john within 30 days after such defect is discovered, DICKEY-john will (at our option) either replace or repair said part. This warranty does not apply to damage resulting from misuse, neglect, accident, or improper installation or maintenance; any expenses or liability for repairs made by outside parties without DICKEY-john’s written consent; damage to any associated equipment; or lost profits or special damages. Said part will not be considered defective if it substantially fulfills the performance expectations. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF MERCHANTABILITY, FITNESS FOR PURPOSE, AND OF ANY OTHER TYPE, WHETHER EXPRESS OR IMPLIED. DICKEY-john neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said part and will not be liable for consequential damages. Purchaser accepts these terms and warranty limitations unless the product is returned within fifteen days for full refund of purchase price. For DICKEY- john Service Department, call 1-800-637-3302 in either the U.S.A. or Canada Headquarters: 5200 Dickey-john Road, Auburn, IL USA 62615 TEL: 217 438 3371, FAX: 217 438 6012, WEB: www.dickey-john.com Europe: DICKEY-john Europe S.A.S, 165, boulevard de Valmy, 92706 – Colombes – France TEL: 33 (0) 1 41 19 21 80, FAX: 33 (0) 1 47 86 00 07 WEB: www.dickey-john.eu Copyright 2012 DICKEY-john Corporation Specifications subject to change without notice.