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Force 5100ex Calibration Manual

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5100ex Calibration Manual
Firmware Version
3.8

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Summary of Contents for Force 5100ex

  • Page 1 5100ex Calibration Manual Firmware Version...

  • Page 3: Table Of Contents

    5100ex Calibration Manual Table of Contents Table of Contents Table of Contents ....................i First Use Guide ....................1 Entering the Calibration Menu ................2 Descriptions of Calibration Values ..............3 Config ............................3 Settings ............................. 3 Import Settings ......................... 3 Export Settings .........................

  • Page 4: Table Of Contents

    5100ex Calibration Manual Table of Contents Unload ............................7 Low Material ..........................7 Aug Rev Valve .......................... 7 Reverse ............................ 7 Clear Jam ..........................7 Two Position Gate ........................8 Aug Fwd ........................... 8 Min DC ............................8 Max DC ............................. 8 Aug Rev ............................
  • Page 5 5100ex Calibration Manual Table of Contents Parent ............................. 13 Min DC ............................ 13 Max DC ........................... 14 Number Of Set Rates ......................14 Set Rates ..........................14 Set Rate 1, Set Rate 2, Set Rate 3, etc................. 14 Prewet ............................15 Options ...........................
  • Page 6 5100ex Calibration Manual Table of Contents Name ............................20 AutoCal ........................... 20 Displacement .......................... 20 Calculating Direct Displacement Using SSC5100 Calibration Values........ 20 Full Speed Displacement Rate ....................21 Number Of Set Rates ......................21 Set Rates ..........................21 Set Rate 1, Set Rate 2, Set Rate 3, etc................. 21 Blast Rate ..........................
  • Page 7 To auto calibrate a direct liquid:..................... 42 Troubleshooting Direct AutoCal ..................... 45 Upgrading Firmware ..................47 To Upgrade the 5100ex Firmware: ..................47 Exporting Calibration Settings ................ 50 To Export 5100ex Calibration Settings: ................. 50 Importing Calibration Settings ................. 52...

  • Page 9: First Use Guide

    5100ex Calibration Manual First Use Guide First Use Guide The first time you configure your 5100ex, you will need to complete the following steps to ensure that your vehicle runs at optimum efficiency: Step: Page Number: 1. Configure your system-wide options.

  • Page 10: Entering The Calibration Menu

    5100ex Calibration Manual Description of Calibration Values Entering the Calibration Menu The Calibration menu is entered by pressing the Calib button in the Main Menu. Unlike the Material Select, Unload, Data, and Version Menus, the Calibration Menu requires the entry of an Access Code before it will appear.

  • Page 11: Descriptions Of Calibration Values

    Settings The settings submenu allows you to export or import calibration settings to and from a USB flash drive. It also allows you to restore the 5100ex to its default settings. Import Settings The Import Settings menu item allows you to import all your configuration settings from a USB flash drive.

  • Page 12: Units

    Profile 1 PWM mode should be used with 3 ohm valve coils. The default value is Normal. Valve Freq The Valve Freq menu item changes the frequency the 5100ex uses to run its valves. The frequency can be set to any value between 50Hz and 250Hz. The default value is 50 Hz.

  • Page 13: Speed

    The Speed menu allows you to configure settings for the vehicle's speedometer input. Type The Type menu item selects the type of speedometer the 5100ex is connected to, either Electronic or Mechanical. Electronic is a high-impedance setting suitable for most modern vehicles.

  • Page 14: Sim Speed

    5100ex Calibration Manual Description of Calibration Values Note that Jump Start speed is not applied when operating in Dust Control and Herbicide mode, regardless of this setting. Sim Speed The Sim Speed menu item enables or disables the simulated speed operation feature.

  • Page 15: Blast Time

    Manual Mode The Manual Mode menu item enables or disables the Manual mode switch on the Operation Screen. When operated in Manual mode, the 5100ex ignores any connected auger feedback sensor and vehicle ground speed and will instead drive the auger output at a fixed percent of maximum speed. The default value is disabled.

  • Page 16: Two Position Gate

    5100ex Calibration Manual Description of Calibration Values Two Position Gate The Two Position Gate menu item allows you to enable gate checking for your granular materials. The default value is Disabled. If enabled, you will be able to select the gate position for each granular material. Two Position Gate uses Input 1 for the low gate sensor and input 2 for the high gate sensor.

  • Page 17: Max Dc

    5100ex Calibration Manual Description of Calibration Values Max DC The Max DC menu item sets the duty cycle required to turn the auger at its fastest rate. Max DC is used in closed, open, manual, and unload modes when Auger Reverse is active and should be configured as accurately as possible. The default value is 75%.

  • Page 18: Parent

    The Materials Enabled menu item changes how many granular materials will be available to the 5100ex during operation. If a granular material is configured with non-default settings and then is disabled with this menu item, its custom settings will not be cleared.

  • Page 19: Gate Position

    5100ex Calibration Manual Description of Calibration Values Gate Position The Gate Position menu item sets the expected gate position for the material. The default value is Low. The Gate Position menu item will only be editable when Config → Auger → Options → Two Position Gate is set to Enabled.

  • Page 20: Set Rate 1, Set Rate 2, Set Rate 3, Etc

    Spinner 1 will run when either Auger Fwd or Rev is active. In most cases, a vehicle is only equipped with one spinner, which will be driven by the Spinner 1 output of the 5100ex. In these cases, set the Parent value to Auger Forward.

  • Page 21: Min Dc

    5100ex Calibration Manual Description of Calibration Values In the 5150 systems, the Parent can only be set to Disabled or Aug Fwd. Min DC The Min DC menu item sets the duty cycle required to turn the spinner at its slowest rate.

  • Page 22: Max Dc

    5100ex Calibration Manual Description of Calibration Values Max DC The Max DC menu item sets the duty cycle required to turn Spinner 2 at its fastest rate. The default value is 75%. Max DC button is disabled when Spinner 2 Parent is Disabled and enabled for all other Parent options.

  • Page 23: Prewet

    The Manual Mode menu item enables or disables the driver-accessible Prewet Manual mode item in the Materials Menu. When operated in Manual mode, the 5100ex ignores any connected prewet feedback sensor and vehicle ground speed and will instead drive the prewet output at a fixed percent of maximum speed.

  • Page 24: Min Dc

    5100ex Calibration Manual Description of Calibration Values Drive Type Operation Hydraulic The prewet set rate is set independently from the auger rate by using a proportional valve on the valve block to control pump speed. The system will be able to control the prewet output in closed, open, and manual application modes.

  • Page 25: Displacement

    5100ex Calibration Manual Description of Calibration Values Using the AutoCal menu item will change the value of the Displacement and Full Speed Displacement Rate menu items. Further refinement can be done by manually changing the Displacement or Full Speed Displacement Rate menu items.

  • Page 26: Set Rate 1, Set Rate 2, Set Rate 3, Etc

    5100ex Calibration Manual Description of Calibration Values Set Rate 1, Set Rate 2, Set Rate 3, etc. The Set Rate menu item sets which gallons per ton or liters per ton setting will be output when the user chooses the corresponding set rate. The default values are shown in the table below.

  • Page 27: Blast Time

    Manual Mode The Manual Mode menu item enables or disables the Manual mode switch on the Operation Screen. When operated in Manual mode, the 5100ex ignores any connected direct feedback sensor and vehicle ground speed and will instead drive the direct pump at a fixed percent of maximum speed. The default value is disabled.

  • Page 28: Max Hertz

    5100ex Calibration Manual Description of Calibration Values Use the green Standby knob to test the direct pump output when adjusting the Max DC value. If the loop mode is set to Closed and a direct flowmeter is installed on the system, the current direct flowmeter frequency will also be shown on the screen to assist with adjustments.

  • Page 29: Full Speed Displacement Rate

    5100ex Calibration Manual Description of Calibration Values × 1000 Full Speed Displacement Rate The Full Speed Displacement Rate menu item allows you to set the maximum amount of direct liquid displaced by the direct pump in a single minute when running at the direct pump maximum speed.

  • Page 30: Boom Width

    The Inputs submenu allows you to configure the settings for the input wires. Input 1, Input 2, Input 3, Input 5, Input 6 The Input menu item allows you to set what 5100ex function will run when the corresponding Input wire is grounded. The default value is Off. If Config →...

  • Page 31: Outputs

    5150 mode is enabled or Config → Application Mode is set to Gran/Dir 3 Lane or Direct 3 Lane, this menu will be disabled. Output 1, Output 2 The Output menu item allows you to set what 5100ex function will activate the aux output. The default value is Off. Function Operation The aux output does nothing.

  • Page 32: Plow Float

    Plow up, plow left, plow right, hoist up, hoist down or auger. The values in this menu are only editable when the Limit Scheme is set to Custom. This feature is only available on the FORCE America ONE systems.

  • Page 33: Alarms

    5100ex Calibration Manual Description of Calibration Values The Hoist Down menu item adjusts the limit percentage for the hoist down output. Auger The Auger menu item adjusts the limit percentage for the auger output. When the auger output is being limited the prewet output will be adjusted as well.

  • Page 34: Prewet

    5100ex Calibration Manual Description of Calibration Values Prewet The Prewet sub menu allows you to configure buzzer settings for the prewet errors and warnings. If Config → Application Mode is set to Direct 1 Lane or Direct 3 Lane or if Prewet is set to disbled, this menu will be disabled.

  • Page 35: Filter Bypass

    5100ex Calibration Manual Description of Calibration Values Filter Bypass The Filter Bypass menu item adjusts the buzzer setting for the filter bypass warning. The options are Silent, Single Chirp, Single Beep, and Solid Tone. The default value is Solid Tone.

  • Page 36: Event Logging

    5100ex Calibration Manual Event Logging Event Logging Event Logging is a method of vehicle usage monitoring that sends spreader data from the 5100ex spreader control to an external device for processing. To use Event Logging with a PreCise™ MRM device: 1.

  • Page 37: Calibrating Axle Pulses By Distance

    Calibrating Axle Pulses By Distance Calibrating Axle Pulses By Distance The 5100ex can automatically set the Calibration → Speed → Axle Pulses value by recording the number of pulses traveled in a mile. Before calibrating the Axle Pulses by distance: 1.
  • Page 38 5100ex Calibration Manual Calibrating Axle Pulses By Distance STEP 7: Press the green Standby knob to stop counting axle pulses. The status should change to “Off”, as shown in Figure 3. Figure 3: Cal By Distance Screen after Counting Pulses STEP 8: Press Ok to save and close the Cal By Distance screen.

  • Page 39: Troubleshooting Calibration By Distance

    5100ex Calibration Manual Calibrating Axle Pulses By Distance Troubleshooting Calibration By Distance Error Message Condition Possible Solutions Value below min. Setting to min. The 5100ex recorded Verify the wiring and less than 5000 connections of the pulses. speedometer cable. This may be caused...

  • Page 40: Autocalibration Of Granular Materials

    AutoCalibration of Granular Materials AutoCalibration of Granular Materials The 5100ex can automatically calculate the displacement and full speed displacement rate values by dispensing granular material. Before you begin make sure Auger Min DC and Max DC have been calibrated. If your system uses a cross auger, also make sure Cross Min DC and Max DC have been calibrated.
  • Page 41 5100ex Calibration Manual AutoCalibration of Granular Materials STEP 12: Press the green, Standby knob to stop dispensing material. The status should change to “Off”, as shown in Figure 5. If your system is an Open Loop system the pulses will be 0.
  • Page 42 25 LBS were dispensed. STEP 15: Press Next to continue. The Full Speed Displacement Rate screen will appear. It will be populated with the value calculated by the 5100ex. You can adjust this value if necessary using the arrow keys. STEP 16: If your system is an open loop system skip to step STEP 18:.

  • Page 43: Troubleshooting Granular Autocal

    5100ex Calibration Manual AutoCalibration of Granular Materials Troubleshooting Granular AutoCal Error Message Condition Possible Solutions Time dispensed is 0. AutoCal Canceled. The system was not Press the green, run. standby pushbutton to dispense material. Pulses measured is 0. AutoCal Canceled.
  • Page 44 5100ex Calibration Manual AutoCalibration of Granular Materials Error Message Condition Possible Solutions Value above max. Setting to max. An inaccurate Verify the integrity of number of pulses the auger feedback were detected. sensor. An inaccurate weight Return to the was entered.

  • Page 45: Autocalibration Of A Prewet Liquid

    AutoCalibration of Prewet Liquid AutoCalibration of a Prewet Liquid The 5100ex can automatically calculate the displacement and full speed displacement rate values by dispensing prewet liquid. Before you begin, make sure Prewet Min DC and Max DC have been calibrated.
  • Page 46 5100ex Calibration Manual AutoCalibration of Prewet Liquid STEP 11: Press the green, Standby knob to stop dispensing liquid. The status should change to “Off”, as shown in Figure 8. If your system is an Open Loop system the pulses will be 0.
  • Page 47 2 gallons were dispensed. STEP 14: Press Next to continue. The Full Speed Displacement Rate screen will appear. It will be populated with the value calculated by the 5100ex. You can adjust this value if necessary using the arrow keys. STEP 15: If your system is an open loop system skip to step STEP 17:.

  • Page 48: Troubleshooting Prewet Autocal

    5100ex Calibration Manual AutoCalibration of Prewet Liquid Troubleshooting Prewet AutoCal Error Message Condition Possible Solutions Time dispensed is 0. AutoCal Canceled. The system was not Press the green, run. standby pushbutton to dispense liquid. Pulses measured is 0. AutoCal Canceled.
  • Page 49 5100ex Calibration Manual AutoCalibration of Prewet Liquid Error Message Condition Possible Solutions Value above max. Setting to max. An inaccurate Verify the integrity of number of pulses the prewet feedback were detected. sensor. An inaccurate weight Return to the was entered.

  • Page 50: Autocalibration Of A Direct Liquid

    AutoCalibration of Direct Liquid AutoCalibration of a Direct Liquid The 5100ex can automatically calculate the displacement and full speed displacement rate values by dispensing direct liquid. Before you begin, make sure Direct Min DC and Max DC have been calibrated.
  • Page 51 5100ex Calibration Manual AutoCalibration of Direct Liquid STEP 11: Press the green, Standby knob to stop dispensing liquid. The status should change to “Off”, as shown in Figure 11. If your system is an Open Loop system the pulses will be 0.
  • Page 52 Press Next to continue. The Full Speed Displacement Rate screen will appear. It will be populated with the value calculated by the 5100ex. You can adjust this value if necessary using the arrow keys. This value will only be correct if you...

  • Page 53: Troubleshooting Direct Autocal

    5100ex Calibration Manual AutoCalibration of Direct Liquid Troubleshooting Direct AutoCal Error Message Condition Possible Solutions Time dispensed is 0. AutoCal Canceled. The system was not Press the green, run. standby pushbutton to dispense liquid. Pulses measured is 0. AutoCal Canceled.
  • Page 54 5100ex Calibration Manual AutoCalibration of Direct Liquid Error Message Condition Possible Solutions Value above max. Setting to max. An inaccurate Verify the integrity of number of pulses the direct feedback were detected. sensor. An inaccurate weight Return to the was entered.

  • Page 55: Upgrading Firmware

    5100ex Spreader Control. Your 5100ex may be upgraded using a USB flash drive. Before upgrading the 5100ex firmware: 1. Save a copy of the 5100ex firmware upgrade in the main folder of your flash drive. Firmware upgrades placed inside subfolders will not be detected by the 5100ex.
  • Page 56 5100ex Calibration Manual Upgrading Firmware Figure 14: Upgrade Firmware screen with File Selector STEP 5: Use the up and down arrow buttons to select an upgrade file to use. If more than 6 upgrade files are available, use the page left and page right buttons on each side of the box to see the other files.
  • Page 57 Figure 16: Firmware Upgrade in Process STEP 8: Wait for the upgrade process to complete. The 5100ex will beep repeatedly until it is finished. Once the upgrade is complete, the 5100ex will restart and return you to the Operation screen.

  • Page 58: Exporting Calibration Settings

    Exporting Calibration Settings Exporting Calibration Settings If you wish to view the calibration settings from a 5100ex or copy settings from one vehicle to another because their hydraulic systems are similar, you may copy them to a USB flash drive using the Export Calibration Settings option.
  • Page 59 Exporting Calibration Settings Figure 18: Export Settings screen with “Connect USB” message STEP 5: Connect the USB drive to the USB port on the left-hand side of the 5100ex. STEP 6: Wait for the Export to complete. Figure 19 will appear.

  • Page 60: Importing Calibration Settings

    If you wish to copy settings from one vehicle to another because their hydraulic systems are identical, you may copy them using the Import Calibration Settings option and a USB flash drive. NOTE: The 5100ex will only import secure 5100ex configuration files (.CALEX). The human- readable exported files (.TXT) cannot not be imported.
  • Page 61 5100ex Calibration Manual Importing Calibration Settings Figure 21: Import Settings screen with File Selector STEP 13: Use the up and down arrow buttons to select an upgrade file to use. If more than 6 configuration files are available, use the page left and page right buttons on each side of the box to see the other files.
  • Page 62 5100ex Calibration Manual Importing Calibration Settings Figure 23: Import Successful Screen STEP 16: Once the import is complete, press OK and you will be returned to the Calibration screen.
  • Page 64 Document No: M0119-M Released: 4/9/2018 Copyright © 2018 FORCE America Inc.

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