Certified Power Freedom Series Acs Calibration Manual
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- Page 1 ACS CALIBRATION MANUAL P/N SG07230014 REVISION E REV DATE 12-8-11 PWR Des Moines, IA (800) 333-7411 Bridgeton, MO (800) 999-7411 Burnsville, MN (800) 289-1330 Perrysburg, OH (800) 374-7411 Mundelein, IL (888) 905-7411...
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Page 2: Table Of Contents
ACS CALIBRATION MANUAL Rev. E SG07230014 Table of Contents EQUIPMENT NEEDED: ..........................3 GETTING STARTED ............................ 4 1. Security Clearance ............................ 4 3. LOG-ON: TECHNICIAN for all calibration procedures: ............4 3. Passwords ..............................6 METRIC MODE............................... 6 CALIBRATING GROUND SPEED (MPH) ................... 7 1. ... - Page 3 ACS CALIBRATION MANUAL Rev. E SG07230014 1. Checklist: Before starting calibration....................35 2. Closed-loop Pre-wet calibration ......................36 3. Fault time-out (closed-loop only) ......................36 4. Open-loop Pre-wet calibration ......................37 5. ON/OFF open-loop Pre-wet calibration ..................37 CLOSED/OPEN LOOP ANTI-ICE CALIBRATION ..............38 1. Checklist: Before starting calibration....................38 2.
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Page 4: Equipment Needed
ACS CALIBRATION MANUAL Rev. E SG07230014 PURPOSE: This document is to service the needs of the individuals responsible to calibrate the vehicle before the snow season. Items include: -Basic material setups (Granular) -Measured Dump procedure -Speedometer calibration and speedometer types ... -
Page 5: Getting Started
ACS CALIBRATION MANUAL Rev. E SG07230014 GETTING STARTED 1. Security Clearance Administrator: HIGHEST LEVEL OF ACCESS o NOT used for calibration. Use Technician level access for calibration. o Use Admin log-in if problem related to equipment setup is found. e.g. changing digital input assignment options, configuration of joystick dead- bands, configuring PWM output assignments. - Page 6 ACS CALIBRATION MANUAL Rev. E SG07230014 Arrow Up/Down, Left/Right keys. Used to navigate through menus, change variables and key in login passwords F1, F2, F3, and ESC keys used for various menu functions. Step 2: LOG-ON; With the Log-On screen displayed as shown below follow the bullet point instructions below.
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Page 7: Passwords
The default factory Admin password is shown above. If it is changed & then lost it will be necessary to contact you local Certified Power Sales Representative for help. Technician and Admin passwords can be viewed/changed under Admin access only. -
Page 8: Calibrating Ground Speed (Mph)
ACS CALIBRATION MANUAL Rev. E SG07230014 CALIBRATING GROUND SPEED (MPH) It is absolutely necessary as part of the calibration process to make sure the ACS MPH [Km/H metric mode] display matches the Truck MPH display. MPH [Km/H metric mode] display ... - Page 9 ACS CALIBRATION MANUAL Rev. E SG07230014 Select into Speedometer Reading and change the “Speedometer reading” value to the vehicle speed you intend to drive at. Drive the vehicle cautiously up to speed. Always keep your eyes on the road and perform speed cal in an area away from other traffic or obstacles.
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Page 10: Configuring Materials
ACS CALIBRATION MANUAL Rev. E SG07230014 CONFIGURING MATERIALS It is important to properly setup all of your materials that will be used on the vehicle. 1. Material Menus Use display arrow keys and F3 “Select” key to navigate through to the “Spreader Settings”... -
Page 11: Material Setup Continued
ACS CALIBRATION MANUAL Rev. E SG07230014 Material Setup continued SET A WEIGHT RATIO. The material used for measured dump should be set to 1:00 ratio typically. o If setting ratios for additional materials, follow the example below. Always divide the new material by the calibrated material to find the new ratio. -
Page 12: Configuring Blast Settings
ACS CALIBRATION MANUAL Rev. E SG07230014 3. Configuring Blast Settings Follow the flow Diagram below to help assist in understanding the Blast features available. Read the descriptions on the next pages. Record your settings along with the material data in the charts provided. If in metric LBS/LM becomes Kg/LnKm. (Blast Settings continued…..) ... -
Page 13: Material Setup Sheet: Keep Track Of Your Material Setups
ACS CALIBRATION MANUAL Rev. E SG07230014 4. Material Setup Sheet: keep track of your material setups! MATERIAL 1 NAME (UP TO 10 DIGITS) WEIGHT Ratio Maximum Rate Increment Rate BLAST SETTINGS Blast type Blast timer Ground Speed Rqd. Blast Setting "Other"... -
Page 14: Prepare For Calibration
ACS CALIBRATION MANUAL Rev. E SG07230014 PREPARE FOR CALIBRATION WARNING: Keep all personnel clear of the vehicle and mechanism before continuing. The feeder is live while in measured dump! Make sure gate is fixed at proper opening for your spreader. Make sure typical baffles/plates/shields are installed. -
Page 15: Load The Vehicle With Material: Load To Typical Capacity
ACS CALIBRATION MANUAL Rev. E SG07230014 MAKE/SET TRIM FINE ADJUSTMENTS 1. Load the Vehicle with material: Load to typical capacity. 2. How to minimize mess: Back-up the vehicle close to the MATERIAL pile as possible. If tailgate spreader, load the auger by raising the bed until auger is loaded. 3. -
Page 16: Important Information About Setting/Saving Trim Settings
ACS CALIBRATION MANUAL Rev. E SG07230014 4. Important information about setting/saving trim settings Note: If setting closed loop trims and the ACS system is not reading pulses from the feeder sensor, the ACS system will not allow TRIM settings to be saved. See below screen. The following points define this feature: ... -
Page 17: Fault Time-Out
ACS CALIBRATION MANUAL Rev. E SG07230014 FAULT TIME-OUT While in the Trim screens, set a fault time-out for the ACS control to switch into Open-Loop mode. Should be adjusted for a value between 1 and 30 seconds. Time-out operation important for default Open-Loop operation to maintain a regulated output in event of sensor failure. -
Page 18: Familiarization Of Measured Dump Procedure
ACS CALIBRATION MANUAL Rev. E SG07230014 o If this vehicle has never been calibrated or has recently had the “EEPROM” cleared by the Administrator; the feeder trims MUST be set first! The controller WILL NOT calculate proper default Open Loop values needed in event there is a sensor failure, if there are NO “Pulse/Minute”... - Page 19 ACS CALIBRATION MANUAL Rev. E SG07230014 Navigate to the measured dump screen shown below using the arrow and F3 keys on the display. Be sure Feeder is loaded with Salt. Safety first! Use caution! Please note the following bullets and study the diagram below: ...
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Page 20: Starting Measured Dump
ACS CALIBRATION MANUAL Rev. E SG07230014 3. Starting Measured Dump! NOTE: VARIABLE GATE: If using a variable gate, you MUST run the same percent of output (Rate) for the duration of measured dump and all gate dumps. You CANNOT vary the output while running the measured dump. Use up ▲ arrow to reach a suitable value like 35% as quickly as possible and keep it there until it’s necessary to stop the output. -
Page 21: Manually Enter Pounds/Pulse [Kilograms/Pulse]
ACS CALIBRATION MANUAL Rev. E SG07230014 o Subtract the weight of the empty bucket from the full bucket weight completing the equation below. The result is the material weight of one bucket FULL - minus the bucket weight. Record the weight. Write it down or you will forget it. o Full bucket weight._______(-)empty bucket weight ______=Material weight________ o Now fill and count each bucket of salt using the //// //// “slash then count”... -
Page 22: Open Loop Measured Dump (No Feeder Sensor Installed)
ACS CALIBRATION MANUAL Rev. E SG07230014 OPEN LOOP MEASURED DUMP (NO FEEDER SENSOR INSTALLED) if you have a feeder sensor installed. Note: Proceed to CLOSED LOOP MEASURED DUMP 1. Checklist for (open-loop) Measured Dump Using Variable height gate? If performing a measured dump with a variable height gate: Set the gate at the most typical opening (calibrate height), perform the measured dump, then continue on to section: GATE CONTROL: CALIBRATING VARIABLE GATE. -
Page 23: Starting Measured Dump
ACS CALIBRATION MANUAL Rev. E SG07230014 Safety first! Use caution! Please note the following bullets and study the diagram below: WARNING: Keep all personnel clear of the vehicle and mechanism before continuing. The feeder is live while in measured dump! ... -
Page 24: Getting Material Weight Dispensed Using A Simple Bathroom Scale & Bucket
ACS CALIBRATION MANUAL Rev. E SG07230014 If USING VARIABLE GATE, record Gate opening (in inches) [centimeters] used during calibrated dump________inches/or _______centimeters. Original weight (recorded above)_______(-) new weight (after dump)______ = total weight of material dispensed.________ Key in the weight of the material for “Pounds Dumped” or [Kilograms Dumped] variable. -
Page 25: Manually Enter Pounds/Minute [Kilograms/Minute]
ACS CALIBRATION MANUAL Rev. E SG07230014 5. Manually enter Pounds/minute [Kilograms/Minute] . It’s not necessary to run measured dump if the LBS/MIN value is known. It can be manually entered at any time. This could be necessary if for any reason calibration variables may have been lost because the valve output module has been replaced or the EEPROM has been cleared by the administrator. -
Page 26: How To Enter Gate Settings
ACS CALIBRATION MANUAL Rev. E SG07230014 2. How to enter Gate Settings Enter all gate opening measurements Enter Pounds/Minute [Kilograms/Minute] values MAXIMUM HEIGHT: Enter the maximum height the Gate is capable of opening. CALIBRATE HEIGHT: Enter the height the vehicle’s Feeder was calibrated at. You should have recorded it under measured dump above. - Page 27 ACS CALIBRATION MANUAL Rev. E SG07230014 Weigh the vehicle again (with the operator) subtracting the new weight from the original weight before the dump process, or else if you are measuring with a bathroom scale and bucket, follow the procedure described under “Bathroom Scale Method”...
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Page 28: Open Loop/Closed Loop Percent Spinner
ACS CALIBRATION MANUAL Rev. E SG07230014 OPEN LOOP/CLOSED LOOP PERCENT SPINNER Percent mode spinner is utilized when the operator needs complete control over the Spinner speed. Percent mode spinner has no interaction with the Feeder. See Lane Control Spinner below if you wish to have the feeder controlled by number of Spinner lanes active (Lane control). -
Page 29: Open Loop Lane Control Spinner
ACS CALIBRATION MANUAL Rev. E SG07230014 OPEN LOOP SPINNER LANE CONTROL Lane control is used when it’s important to keep uniform Lbs/Lane mile (Lb/LM) [Kg/LnKm metric mode ] across all lanes while the truck is dispensing material. The spinner controls the feeder output. As the spinner is changed from 1 to 2 lanes, the feeder output is automatically doubled or tripled or quadrupled if running 4 lanes. -
Page 30: Closed Loop Lane Control Spinner
ACS CALIBRATION MANUAL Rev. E SG07230014 CLOSED LOOP SPINNER LANE CONTROL Lane control is used when it’s important to keep uniform Lbs/Lane mile (Lb/LnM) [Kg/LnKm metric mode ] across all lanes while the truck is dispensing material. The Spinner controls the feeder output. As the Spinner is changed from 1 lane to 2 lanes, the feeder output is automatically doubled or tripled or quadrupled if running 4 lanes. -
Page 31: Zero Velocity Spinner
ACS CALIBRATION MANUAL Rev. E SG07230014 ZERO VELOCITY SPINNER If you don’t have a Zero Velocity Spreader installed on your vehicle please disregard this section. 1. Basic Operating principle of Zero Velocity: Material being distributed to the road surface is accelerated at a speed equal to the current vehicle speed in Miles Per hour or [Kilometer per hour metric mode ] but in opposite direction to which the vehicle is traveling therefore canceling material velocity in relation to the road surface. -
Page 32: Trim Adjustment
ACS CALIBRATION MANUAL Rev. E SG07230014 3. Trim Adjustment Perform Trim adjustments as detailed in the previous section for Open/Closed Loop percent mode spinner after reading the bulleted items outlined below. o Trim adjustments are best done at the salt pile to help minimize mess. o Spinner MIN TRIM should be set as low as possible. -
Page 33: Getting Ready For Calibration
ACS CALIBRATION MANUAL Rev. E SG07230014 5. Getting ready for calibration It is necessary to calibrate a 2-point “Low Setting” and a “High Setting”. See illustrations and instructions below. Note: “Low Speed” values shown. Use display ▲▼ arrows to control ON/OFF control and speed in 5% increments of ZV spreader. -
Page 34: High Speed Calibration
ACS CALIBRATION MANUAL Rev. E SG07230014 7. High Speed Calibration Repeat the same procedure for High Speed calibration. Use display Page Dn / F2 key or arrow keys to navigate to the ‘High Speed page’. It will be detailed as shown below. - Page 35 ACS CALIBRATION MANUAL Rev. E SG07230014...
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Page 36: Closed/Open Loop Pre-Wet Calibration
ACS CALIBRATION MANUAL Rev. E SG07230014 CLOSED/OPEN LOOP PRE-WET CALIBRATION 1. Checklist: Before starting calibration. Tanks with liquid in them. Use caution if using straight water. Water will freeze causing major damage to all system components. If water is to be used for calibration, be sure to flush system thoroughly with windshield washer fluid when calibration is completed to remove all water. -
Page 37: Closed-Loop Pre-Wet Calibration
ACS CALIBRATION MANUAL Rev. E SG07230014 2. Closed-loop Pre-wet calibration Navigate to the Pre-wet Valve setup screen shown below using the display’s arrow and F3 keys on the display panel. Use the illustrations below as a guide. Set the flow-meter K-Factor Note: Flow-meter is set to Enter directly: The flow-meter K-Factor. -
Page 38: Open-Loop Pre-Wet Calibration
ACS CALIBRATION MANUAL Rev. E SG07230014 4. Open-loop Pre-wet calibration Typical Min Trim setting for a Hydraulic Stack-driven pre-wet. Typical Max Trim setting for a Hydraulic Stack-driven Pre-wet. Do not to exceed 40% max trim value for typical Hypro type Hydraulic motors. -
Page 39: Closed/Open Loop Anti-Ice Calibration
ACS CALIBRATION MANUAL Rev. E SG07230014 CLOSED/OPEN LOOP ANTI-ICE CALIBRATION 1. Checklist: Before starting calibration. Tanks with liquid in them. Use caution if using straight water. Water will freeze causing major damage to all system components. If water is to be used for calibration, be sure to flush system thoroughly with windshield washer fluid when calibration is completed to remove all water. -
Page 40: Fault Time-Out (Closed-Loop Only)
ACS CALIBRATION MANUAL Rev. E SG07230014 3. Fault time-out (closed-loop only) While in the Trim screens (see above illustrations), set a fault time-out for the ACS control to switch into Open-Loop mode. Should be adjusted for a value between 1 and 30 seconds. 4.