Dickey-John Control Point User manual
OPERATOR'S MANUAL
CONTROL POINT™ SYSTEM DESCRIPTION/ 1
11001-1100-199904 Revision A
CHAPTER 1 – SYSTEM DESCRIPTION
The DICKEY-john Control Point™ system uses three-channels (three separate
controlled servo loops) on spreader vehicles to simultaneously control the
spreading of granular and liquid ice-control materials. Two channels control
granular and liquid application rates and the third channel precisely controls
spinner speed to maintain even material coverage over the desired spread
width. The dispensing rate varies directly with ground speed to ensure accu-
rate product application.
Material can also be spread at a preset “BLAST” application rate. This is
normally a very large rate to instantly adjust the target APR (application rate)
for covering bridges and intersections with a much heavier amount of material.
GRANULAR CHANNEL CONFIGURATION
The granular channel controls the amount of material dumped onto the
spinner plate(s). To do this, the Control Point™ monitors a tachometer style
feedback sensor located on the V-box drag chain or tailgate auger. A resultant
drive signal adjusts the conveyor mechanism speed to deliver the target
application rate (APR) by regulating the hydraulic valve position.
Figure 1. System Components
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LIQUID CHANNEL CONFIGURATION
The liquid channel controls the application rate of prewetting or deicing
materials. When prewetting, the Control Point™ Console monitors a flowmeter
style feedback sensor. When deicing, either a flowmeter or pressure style
feedback can be used. Using feedback data, the pumping mechanism output
adjusts the target application rate by either regulating pump speed or flow
blocking.
Deicing systems use up to five boom inputs for applying material to more than
one lane at a time.
SPINNER CHANNEL CONFIGURATION
The spinner channel controls the spinner plate(s) speed with either a closed-
loop (precision) or an open-loop configuration. In the closed-loop configura-
tion, a tachometer style feedback sensor, mounted on the spinner assembly,
monitors spinner activity. Using the feedback data, the spinner mechanism
speed adjusts for the target setting by controlling the hydraulic valve position.
In open loop systems, the hydraulic valve position is relative to the WIDTH
ADJUST knob setting on the Control Point™ Switch Module.
The customer must determine the spread-width accuracy needed. DICKEY-
john Marketing and Product Service personnel are available with additional
information to help with this decision.
PRODUCT APPLICATION MECHANISMS
The granular and spinner channels use, in addition to feedback (shaft rotation)
sensors, either servo valve actuators or proportional valves to control the
product application and spinner speed. The liquid channel uses, in addition to
feedback sensors (flowmeter or pressure transducer), a liquid pump to control
product application. The liquid pump output is controlled by either a 12 volt
DC motor, servo valve actuator, or proportional valve.
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CONTROL POINT™ SYSTEM DESCRIPTION/ 3
11001-1100-199904 Revision A
SYSTEM FEATURES AND CAPABILITIES
1. Easy installation - surface-mounting Console kit.
2. Switch Module located anywhere in the cab to allow optimum
placement for the operator.
3. Large 160X128 dot-matrix LCD display with backlighting for
nighttime viewing.
4. Single Console button for system power on/off and screen selec-
tion.
5. RS-232 port for PC uploading and downloading of data.
6. Detachable keyboard for easy supervisor programming and
calibration using multilevel, menu-driven screens.
7. Custom programming available to minimize setup time.
8. Compatibility with a variety of sensors, servo valve actuators, and
proportional valves available from DICKEY-john or other manu-
facturers.
9. Audible and visual alarms for system and operator errors.
SYSTEM COMPONENT DESCRIPTIONS
A DICKEY-john Control Point™ system consists of six basic components;
(1) Console, (2) Switch Module, (3) ground speed sensor, (4) feedback devices to
monitor material application, (5) actuator devices to regulate material application,
and (6) harnesses to interconnect all system devices. The detachable keyboard
(optional) and PC (not provided) are programming aids and not actually a part of
a basic Control Point™ system.
Figure 1 illustrates the Console, Switch Module, and keyboard. Figure 2 shows
components in a block diagram. The Console and Switch Module are located
inside the truck cab. These two items may be mounted side-by-side or the Switch
Module can be positioned for operator convenience.
A. Console
The Console displays information on a dot-matrix LCD and uses a single push-
button switch to control system power and to view several operator screens.
Using an external keyboard for programming and placing operator controls on
the Switch Module greatly simplify the Console.
An RS-232 port connector, located on the Switch Module harness, permits data
transfer to and from the Console. This port interfaces to a PC for downloading
accumulator and alarm information. When replacing a console or when identical
vehicles require programming/calibrating, uploading and downloading configura-
tion information through the port is extremely useful. For multiple units, only one
system needs to be programmed and then the constants can be transferred
(downloaded) from that console, stored in a PC file, and uploaded to the other
vehicle's console. Note: This is only useful on identical vehicles.
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B. Switch Module
The Switch Module harness plugs into the Console and contains connectors for
both keyboard and PC interface as described above.
The operator controls the real-time functions of the Control Point ™ system
from the seven switches on the Switch Module. (See Figure 3).
C. Keyboard
The keyboard is the means the operator uses to program and calibrate the
system. The 86-key, alphanumeric, PC-compatible keyboard has been environ-
mentally hardened for use in the ice-control field. After programming and
calibration are finished, the keyboard is usually disconnected and stored.
D. 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 wide variety of electronic
and mechanical speedometer sensors, including Hall-Effect and Reluctance
sensors.
Figure 2. System Block Diagram
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E. Feedback Sensors
The 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) or system pressure (analog). A
liquid prewetting system only accepts pulsed feedback while higher capacity
anti-icing systems accept either pulsed or analog.
F. Actuator Devices
Actuator devices regulate material flow for accurate control of product applica-
tion rates. Normally, granular and spinner channels regulate the hydraulic oil
flow rate to a motor. Liquid channels use several different configurations. Many
prewetting systems use a DC pump to regulate flow by controlling pump speed.
Other systems use hydraulically driven pumps similar to agricultural applica-
tions.
G. Hopper Level Sensor (Optional)
The optical light beam of this level sensor is blocked by the granular material in
the spreader bed. When the material level falls beneath the sensor mounting
level, a repetitive beep sounds and an appropriate message displays in the
warning/alarm area of the OPERATE screen.
I. Harnesses
The Main Harness assembly connects the Console to the ground speed sensor,
feedback sensors, channel valve (or DC motor) actuators, vehicle battery,
ignition, and additional optional connections (including two-speed axle, hopper
level sensor, and boom sense inputs). An optional Extension Harness, allows
the Main Harness to extend outside the cab, contains duplicate connectors to
permit hookup flexibility. Other extension harnesses are available to allow
flexible sensor arrangement.
HOW TO OBTAIN TECHNICAL SUPPORT
For prompt and courteous assistance and answers to your questions, call
DICKEY-john Technical Support at (217) 438-3371 or Fax (217) 438-6012 or
438-6539. For toll-free calls in either the USA or Canada, dial 1-800-637-3302.
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CHAPTER 2 – OPERATING PROCEDURES
This chapter explains how the operator (driver) of an ice-control vehicle uses
the controls on the Switch Module and Console to perform standard operator
functions. Note: The detachable keyboard (optional) is required to program and
calibrate the system as described in the next Chapter.
Depending upon programming, the operator can view three or four different
screens of data. The OPERATE screen is the home screen for monitoring
spreader operation; the remaining screens are supportive – MATERIAL
SELECT/MANUAL SPEED, CURRENT TOTALS, and SEASON TOTALS.
The MATERIAL/MANUAL SPEED SELECT screen is only accessible if the
system is stationary (no ground speed).
PREPARING FOR OPERATION
Perform the following procedures only after the system is installed, properly
programmed and calibrated. Practice the following procedures with the vehicle
stationary to gain familiarity with the operating controls and screens before
applying product.
Figure 3. Switch Module Controls and Definitions
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STARTING THE SYSTEM
1. Verify the MASTER Switch on
the Switch Module is in the
OFF position (See Figure 3).
If the Master Switch is in the
AUTO position during power up,
a warning message with audible
alarm occurs until the switch is
turned OFF (See Figure 4).
2. Turn on the ignition switch.
If the Console was on when the
ignition was last turned off, the
display comes on with the
ignition switch. A screen briefly
shows the DICKEY-john logo
followed by the OPERATE screen (See Figure 6).
If the console does not power on, the console button was used to
properly power down the unit. Proceed to Step 3.
3. Briefly press the Console button (less than a second) to apply
power to the Console (See Figure 5).
If the button is held too long, a beep sounds indicating
the Operate screen is skipped and an accessory screen
appears instead (This screen described later). If the beep
is heard, turn the console off as indicated in Step 4 and
start again.
During start-up (power up), the Console automatically
closes all system actuators and performs self-tests, includ-
ing system configuration and application data. If an error
occurs at power up or during operation, an appropriate
error message displays with recovery information.
4. Turn the Console off by pressing and holding the
Console button until a beep sounds and the text on
the screen disappears (approx. 3 seconds) and then
release.
Power is removed when the screen goes dark. To restart,
repeat Step 3.
Figure 4. Master Switch
Warning Message
Figure 5. Console Showing Functional Items
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11001-1100-199904 Revision A
OBSERVING THE OPERATE SCREEN DIVISIONS
1. Study the OPERATE screen layout (See Figure 6).
Three windows across the upper portion display Granular, Liquid,
and true (actual) Ground Speed data. Directly above, status of the
booms graphically display. Below the windows, error messages
appear briefly for system errors along with an audible alarm. In the
lower third, the Spread Width Bar graphically indicates percentage
of spinner activity via a black bar. At the bottom, the current date
and time display.
2. At the Switch Module, turn the Granular and Liquid ON/OFF
switches off, then back on again (See Figure 3).
Notice, the window for each product reads OFF and then returns to
the material and target (APR) values again.
Ground speed is independent of product application and therefore
displays only when the vehicle is moving.
Product application begins with vehicle motion if the Master Switch
is in the AUTO position. The actual APRs display in roughly twice
the size of the target APRs (See Figure 7).
3. Change the target rate of either product channel by pressing
the respective “INC/DEC +/-” switch on the Switch Module.
The value increments/decrements as a beep is heard for each inc/
des step. If the switch is held, the value repeats until reaching a
preset limit. If changed while the vehicle is moving, the new target
APR displays for approximately two seconds, then reverts to the
actual APRs.
Figure 6. Divisions of the OPERATE Screen
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4. Rotate the WIDTH ADJUST knob on the Switch Module
while observing the SPREAD WIDTH bar on the display.
The rotational speed of the spinner changes with the knob setting.
The horizontal bar graphically represents the position of the
SPREAD WIDTH knob. The bar is at the 100% position when the
knob is fully clockwise, corresponding to maximum spinner speed.
The operator determines the correct setting by observing the spread
pattern. The bar is hollow until the spinner is operating.
5. Note the date and time across the bottom edge of the screen.
6. Observe the boom graphics across the top of the screen.
All boom sections appear as rectangle blocks during anti-ice
operation. Each section is hollow until activated.
7. Observe the area for alarm messages.
Alarm messages appear (flashing) in the middle of the screen, above
the SPREAD WIDTH bar (See Figure 7).
Figure 7. OPERATE Screen Showing Product Application
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