Bosch Rexroth CS 440RC Detailed Configuration And Set-Up Manual Download Page 7

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Bosch Rexroth Canada ı 03.10.2011 ı Revision 5.4

Liquid

To spray bar

HYDRAULIC PUMP

SOLENOID

OPERATED

VALVES

CS-440 MICROPROCESSOR

Ground Speed Sensor

Flow meter

Liquid pump,
driven by a
hydraulic
motor

Hydraulic

Reservoir

Liquid

To spray bar

HYDRAULIC PUMP

SOLENOID

OPERATED

VALVES

CS-440 MICROPROCESSOR

Ground Speed Sensor

Flow meter

Liquid pump,
driven by a
hydraulic
motor

Hydraulic

Reservoir

Liquid

To spray bar

HYDRAULIC PUMP

SOLENOID

OPERATED

VALVES

CS-440 MICROPROCESSOR

Ground Speed Sensor

Flow meter

Liquid pump,
driven by a
hydraulic
motor

HYDRAULIC PUMP

SOLENOID

OPERATED

VALVES

SOLENOID

OPERATED

VALVES

CS-440 MICROPROCESSOR

Ground Speed Sensor

Flow meter

Liquid pump,
driven by a
hydraulic
motor

Hydraulic

Reservoir

Hydraulic

Reservoir

A typical system consists of a closed loop solid de-icer system. Components making

up a system consist of the following:

•

CS-440RC Microprocessor

•

Electrically operated conveyor hydraulic valve

•

Electrically operated spinner hydraulic valve

•

Conveyor speed sensor

•

Ground speed sensor

•

Conveyor Motor

•

Spinner Motor

There are other components such as cables and hydraulic hoses to consider. These

are covered in the Installation Manual and are not covered in the Configuration and

Setting up Manual.

1.3 A Typical Pre-wetting System

Pre-

wetting

The Pre-wetting system:

•

CS-440RC Microprocessor

•

Electrically operated liquid pump hydraulic valve

•

Flow meter

Summary of Contents for Rexroth CS 440RC

Page 1: ...CS 440RC Solid De icer Controller Detailed Configuration and Set up Manual ...

Page 2: ...it 17 4 1 3 Auto Calibration Using the GPS Provider s Ground Speed Signal 17 4 1 4 Auto Calibration Using the Vehicle s Speedometer 17 4 1 5 Auto Calibration Procedure 17 4 1 6 Verification of Ground Speed 17 4 1 7 Simulated Ground Speed 19 5 5 5 5 Conveyor Hydraulic Valve Configuration Conveyor Hydraulic Valve Configuration Conveyor Hydraulic Valve Configuration Conveyor Hydraulic Valve Configura...

Page 3: ...When Liquid is Applied 33 10 3 Naming the Material 34 10 4 Programming the Material Spread Rates 34 10 5 Nulling of the Pre wet Valve Solenoid 34 10 5 1 Minimum Nulling 34 10 5 2 Maximum Nulling 35 10 5 3 Auto Nulling 35 10 6 Automatic Calibration 36 11 11 11 11 Anti Anti Anti Anti icing Mode icing Mode icing Mode icing Mode 3 3 3 38 8 8 8 11 1 Simulated Anti icing Mode 38 11 1 1 Selecting the Sim...

Page 4: ...on Temperature Sensor Configuration Temperature Sensor Configuration 46 46 46 46 15 1 Selecting the Temperature Sensor Manufacturer 46 15 2 Temperature Compensation 46 16 16 16 16 Error Message Configuration Error Message Configuration Error Message Configuration Error Message Configuration 47 47 47 47 16 1 Operational Errors 47 16 2 Inputs and Outputs Errors 47 16 3 Error Time Delay 48 16 4 Error...

Page 5: ... Pilot technology both to the computer as well as from the computer back to the CS 440RC The system can be configured directly into the CS 440RC in the vehicle or a standard configuration can be generated in the computer software and transferred to the CS 440RC This technique saves time as much of the configuration data is the same for all vehicles and in this manner configuring only needs to be d...

Page 6: ...6 57 Bosch Rexroth Canada ı 03 10 2011 ı Revision 5 4 1 1 CS 440RC Front Layout 1 2 A Typical Solid De icer Salt Sand System ...

Page 7: ...PERATED VALVES CS 440 MICROPROCESSOR Ground Speed Sensor Ground Speed Sensor Flow meter Flow meter Liquid pump driven by a hydraulic motor To Hydraulic Reservoir To Hydraulic Reservoir A typical system consists of a closed loop solid de icer system Components making up a system consist of the following CS 440RC Microprocessor Electrically operated conveyor hydraulic valve Electrically operated spi...

Page 8: ...s to consider These are covered in the Installation Manual and are not covered in the Configuration and Setting up Manual This manual has been broken down in sections covering each of the components as well there are sections dealing with calibration etc See the Table of Contents pages 2 4 for the complete list of topics ...

Page 9: ...Set up any individual section To set up the CS 440RC a programming key is needed this is to prevent unauthorized personnel from making adjustments Make sure only authorized staff has access to the key Insert the key and turn same turn and the screen to the left will appear Using the navigation button move the cursor to the area to be configured and press the Enter button Place the cursor in front ...

Page 10: ...ble of Contents for the proper page number and instruction for each section To return to the first screen press the Escape button Using the navigation button move the cursor in front of MATERIAL SETUP and press the Enter button The screen to the left will appear Each of these sections can be configured from this screen refer to the Table of Contents for the proper page number and instruction for e...

Page 11: ...ss the Enter button The screen to the left will appear Each of these sections can be configured from this screen refer to the Table of Contents for the proper page number and instruction for each section To return to the first screen press the Escape button When Configuration and Setting Up are completed remove the programming key ...

Page 12: ...utton There are 8 digits available for the name using the Left or Right navigation button move the cursor under the letter or number to be added or changed Using the Up or Down navigation button change the letter or number as required Once all the letters or numbers have been added or changed Press the Enter button Press the Escape button twice to return to the first screen 3 3 Setting the Truck I...

Page 13: ... appear Automatic Automatic Automatic Automatic Is the wt distance Closed Loop selection In this mode both the Ground Speed Sensor and the Conveyor Speed Sensor are in use Open Loop Open Loop Open Loop Open Loop In this mode only the ground speed sensor is in use Manual Manual Manual Manual In this mode neither the ground speed sensor nor the conveyor speed sensor is in use Closed L Closed L Close...

Page 14: ...f the item to be edited and press the Enter button Using the Left or Right navigation button move the cursor under the number to be changed Using the Up or Down navigation button change the number as required Once all the numbers have been changed press the Enter button Once all the items have been corrected press the Escape button three 3 times to return to the first screen 3 7 Enabling GPS Mode ...

Page 15: ... accuracy level for each technique is reflected in the numbering with number one 1 being the most accurate 1 Driving the vehicle over a measured distance By measuring out the distance of one 1 KM for metric system users or one 1 Mile for Imperial system users and driving the vehicle over this measured distance allows the CS 440RC to count the pulses it receives over this distance This pulse count ...

Page 16: ...e section of road and mark the starting and end point with clearly visible markers Drive the vehicle to the starting point and stop with the vehicle s front bumper in line with the marker On the CS 440RC press the Escape button The programming key is not needed for this With the cursor arrow pointing at Trip Summery press Enter The top line of the transaction screen will reflect XXXXX KM Mile Tota...

Page 17: ...peed Signal on Using the GPS Provider s Ground Speed Signal Follow the auto calibration procedure below hold the vehicle speed to the speed indicated on the GPS provider s system Note cell phone communication with the GPS provider will be necessary 4 1 4 4 1 4 4 1 4 4 1 4 Auto C Auto C Auto C Auto Ca a a alibration Using the Vehicle s Speedometer libration Using the Vehicle s Speedometer libration...

Page 18: ...verification is carried out for example using a hand held GPS navigator and the ground speed is found to be inaccurate an adjustment in the pulses per KM or Mile can be made on the SPEED INPUT screen to correct this During the verification process the screen to the left would be on the display While driving the vehicle the vehicle speed reading on this screen is compared to the GPS speed reading I...

Page 19: ...t a key Make sure that the vehicle is stationary ground speed 0 and display is on main OPERATION SCREEN as shown to the left Hold Enter button down press Escape button and let go both buttons at the same time Press Escape to switch to OPERATOR SCREEN as shown to the left Press Up and Down buttons to adjust simulated ground speed as shown to the left The speed will increase and decrease in 5 mile o...

Page 20: ...he maximum motor design speed Forward Gain is another factor to be considered for prompt start up This is built into the system to overcome an inherit hydraulic motor pulsing problem Once the hydraulic motor inlet oil pressure is sufficient to create motion the motor will pulse during start up until it receives enough oil flow for continuous motion As continuous motion is required for even spreadi...

Page 21: ...nd using the navigational arrow move the cursor under the last digit The conveyor should now be turning and the RPM reading should show in the lower corner Using the Up or Down navigational arrows adjust the RPM to the maximum hydraulic motor design RPM If the hydraulic motor specs are not available slowly increase the speed until there are no further increases in the RPM reading Now slowly lower ...

Page 22: ...ve any more pulses from the sensor indicating the conveyor has stopped Note Auto Nulling may take place twice for low speed hydraulic motors as the controller will verify the first readings to make sure the small range between minimum and maximum is correct When Auto Nulling is completed the screen will return to the previous screen 5 1 4 Forward Gain 5 1 4 Forward Gain 5 1 4 Forward Gain 5 1 4 Fo...

Page 23: ... per Revolution Pulses per Revolution Pulses per Revolution Standard externally mounted sensor White Hydraulic Motor Parker Hydraulic Motor Char Lynn Hydraulic Motor 16 50 30 40 Insert the programming key select SENSORS AND VALVES and select CONVEYOR SETUP The screen to the left will appear Use the Up or Down navigation buttons move the cursor to CONVEYOR SENSOR and press the Enter button The scre...

Page 24: ...tion buttons move the cursor to the 00 Min option and press the Enter button 4 Use the Right or Left navigation button to move the cursor under the number to be changed 5 Using the Up or Down navigation buttons change the setting to match the gate opening 6 Note the Volts reading will change to reflect the actual reading from the sensor 7 Once the numbers have been changed to match the gate openin...

Page 25: ...linder and gate read back sensor Select SENSOR VALVES GATE screen Follow the instruction in section 7 2 Lower the gate all the way down by pressing DOWN button Once the gate is at the bottom position move cursor to 00 Min press ENTER to set min position and press ENTER again to record the setting Then Raise the gate all the way up by pressing UP button Once the gate is at the up position move curs...

Page 26: ...button move to the letter or number to be added or changed Using the Up or Down navigation button change the letter or number as required Once all the letters or numbers have been added or changed press the Enter button 8 3 Calibration Procedure Insert the programming key select MATERIAL SETUP and select the desired solid The screen to the left will appear 8 3 1 Gate Setting for C 8 3 1 Gate Setti...

Page 27: ...te The screen message is a warning that the system will run during the ote The screen message is a warning that the system will run during the ote The screen message is a warning that the system will run during the ote The screen message is a warning that the system will run during the calibration process make sure all personnel is clear of moving parts calibration process make sure all personnel ...

Page 28: ...aterials to be calibrated 8 4 Verifying Calibration with Simulated Ground Speed Obtain a material catch container with a known volume and weight capacity The higher the capacity the more accurate it will be Calculate the time required to fill the box with a specific rate and vehicle speed 1 Place the catch box under the chute 2 Set the simulated ground speed to the determined speed Press Enter the...

Page 29: ...tons move the cursor to the desired option and press the Enter button The screen will return to the previous screen Press the Escape button twice to return to the first screen 9 2 Selecting the Spinner Stop Mode Insert the programming key select SYSTEMS select OPERATION SETTINGS and select SPINNER OPTIONS The screen to the left will appear Always On Always On Always On Always On Once its operation...

Page 30: ...se the Down navigation button to move the cursor to first line and press the Enter button Using the Left or Right navigation button move to the number to be changed Using the Up or Down navigation button change the number as required Once all the numbers have been changed as desired press the Enter button Move down to the next line and repeat the process Press the Escape button three times to retu...

Page 31: ...s per Revolution Insert the programming key select SENSORS AND VALVES select SPINNER SETUP and select SPINNER SENSOR The screen to the left will appear Determine the pulses per Revolution from the manufacturer s specifications Use the Up or Down navigation button to move the cursor in front of 0022 Pulses Rev and press the Enter button Using the Left or Right navigation button move to the number t...

Page 32: ...er RPM Maximum Spreading Speed Use the Down navigation button to move the cursor in front of 11 PPS Factor and press the Enter button Using the Left or Right navigation button move to the number to be changed Using the Up or Down navigation button change the number as required Once all the numbers have been changed press the Enter button Press the Escape button three times to return to the first s...

Page 33: ...te Manual Manual Manual Manual M M M M The pre wetting system is set to manual mode Return Oil Pre Return Oil Pre Return Oil Pre Return Oil Pre wet wet wet wet S S S S The pre wet rate is a variable rate system the pre wetting system is operated by the conveyor motor exhaust oil Using the navigation buttons move the cursor to the desired option and press the Enter button The screen will return to ...

Page 34: ...iquid rates are in ltrs tonne or gallons per tonne Select the proper rates from percentage pre wetting rate charts Use the Down navigation button to move the cursor to the desired line to be changed and press the Enter button Using the Left or Right navigation button move to the letter or number to be added or changed Using the Up or Down navigation button change the letter or number as required O...

Page 35: ... arrow move the cursor in front of Max Out Press the Enter button and using the navigational arrow move the cursor under the last digit The PRE WETTING PUMP should now be turning and the LPM reading should show in the lower corner Using the navigational arrows adjust the LPM to the maximum operational flow requirement The reading on the screen is of maximum controller output allowed for output to ...

Page 36: ...the left will appear Use the Down navigation button to move the cursor to RUN CALIBRATION and press the Enter button The screen to the left will appear N N N Note ote ote ote Screen message is a warning that the system will run during the Screen message is a warning that the system will run during the Screen message is a warning that the system will run during the Screen message is a warning that ...

Page 37: ...t Left navigation arrows move the cursor under the number to be changed Using the Up Down navigational arrow enter the volume of the material Once the proper volume has been entered press the Enter button Using the Down navigational arrow move the cursor to ACCEPT VALUE Press the Enter button again to confirm acceptance of the weight value the screen will return to the starting screen Note The pul...

Page 38: ...System for Simulated Anti Setting the System for Simulated Anti Setting the System for Simulated Anti Setting the System for Simulated Anti icing icing icing icing Using the navigation buttons move the cursor to MATERIAL SETUP select PREWET 1 and press the Enter button The screen to the left will appear 11 1 3 11 1 3 11 1 3 11 1 3 Change LIQUID Change LIQUID Change LIQUID Change LIQUID1 to Read PR...

Page 39: ...ON Have the operator set up the system for PRE WETTING on start up once anti icing is to be used the operator switches the selector switch to ANTI ICING and the operator display screen will now reflect anti icing conditions 11 2 Multiple Boom Anti icing In the three booms anti icing mode the vehicle is equipped with booms for single double or three lane applications When selecting each boom the ap...

Page 40: ...tton move to letter to be changed Using the Up or Down navigation button change the letter as required Once all the letters have been changed press the Enter button 11 2 4 11 2 4 11 2 4 11 2 4 Entering the Anti Entering the Anti Entering the Anti Entering the Anti icing Liquid Rates icing Liquid Rates icing Liquid Rates icing Liquid Rates The screen rates are in ltr or gal per ton treat this as lt...

Page 41: ...trolled at that rate OFF OFF OFF OFF The BLAST function is turned off and cannot be activated by the operator 12 2 Setting the Fixed Ratio Pre wetting Blast Mode of Operation Insert the programming key select SYSTEM SETUP select BLAST MODE and select PREWET The screen to the left will appear In the Fixed Pre wetting mode the pump is not capable of producing the required flow for the BLAST mode Tur...

Page 42: ...under the number to be changed Using the Up or Down navigation button change the number as required Once all the numbers have been changed press the Enter button Press the Escape button three times to return to the first screen 12 5 Blast Rate Setting the Closed Loop Insert the programming key select MATERIAL SETUP and select SOLID 1 SALT the screen to the left will appear Use the Down navigation ...

Page 43: ... SETTINGS and select GATE SETTING The screen to the left will appear Use the Down navigation button to move the cursor to 05 and press the Enter button Using the Left or Right navigation button move to the number to be changed Using the Up or Down navigation button change the number as required Once all the numbers have been changed press the Enter button Press the Escape button three times to ret...

Page 44: ...twice to return to the first screen 13 4 Setting the Operator Options Insert the programming key select SYSTEM SETUP select OPERATION SETTINGS and select OPERATOR OPTIONS The screen to the left will appear Note MODE is the mode of operation for the liquid system Use the Down navigation button to move the cursor to DESIRED OPTION and press the Enter button Press the Escape button twice to return to...

Page 45: ... ALARM SPEED The screen to the left will appear Use the Down navigation button to move the cursor to 88 KMH MPH and press the Enter button Using the Left or Right navigation button move to number to be changed Using the Up or Down navigation button change the number as required Once all the numbers have been changed press the Enter button Press the Escape button twice to return to the first screen...

Page 46: ... and press the Enter button 15 2 Temperature Compensation Then enter the desired temperature compensation percentage E g 2 means the application rate will increase by 2 for each degree the temperature goes down since the last dial selection 00 turns this feature off Press the Escape button twice to return to the first screen Note In order to reduce rate fluctuations the temperature must change 3 d...

Page 47: ...and equipment could start without warning BLAST TOO LONG The Blast mode exceeded its time limit OVERSPEED Vehicle speed exceeded the preset limit CALIBRATION The setting desired cannot be produced check settings 16 2 Inputs and Outputs Errors Insert the programming key select ERROR CONFIG and select INPUTS AND OUTPUTS The screen to the left will appear Error Message Error Message Error Message Err...

Page 48: ...elect OPERATION The screen to the left will appear Use the Down navigation button to move the cursor to the desired error function and press the Enter button The screen to the left will appear Use the Down navigation button to move the cursor to 05 Seconds delay and press the Enter button Using the Left or Right navigation button move to number to be changed Using the Up or Down navigation button ...

Page 49: ... percentage of the maximum conveyor speed neither ground speed nor conveyor speed input are available OUTPUT FROZEN All outputs to the valves are frozen and the system will be operating Outputs return to normal control once the operator acknowledges the alarm OUTPUT TO ZERO All outputs go to zero when the error is activated and will remain at zero once the operator acknowledges the alarm The appli...

Page 50: ...iquid material GSLP gate or solid or liquid change when leaving PROGRAM mode CTUP control mode or system units change leaving PROGRAM mode SPIN Spin Rate change when in g m 2 mode Solid Rate Normally kg km PreWet Rate Normally liter tonne Boom Status LCR to indicate whether left centre or right boom is on Ground Speed Calculated speed based on Total Time and Total Distance Total Time Total Time of...

Page 51: ...as an INIT event 4 What are the CS 4 What are the CS 4 What are the CS 4 What are the CS 440RC 440RC 440RC 440RC error codes and error messages error codes and error messages error codes and error messages error codes and error messages 01 Under Application of Solid 02 Under Application of Liquid 03 Output Non Zero on a start up 04 Blast too long 05 Over Speed Warning 06 Sensor Calibration Error 0...

Page 52: ... Ground Speed and how to set up What is the Simulated Ground Speed and how to set up It simulates the ground speed signal and to allows for diagnostics and calibration without moving To set it up here are the steps Set to program mode by turning the programming key Select SYSTEM SETUP SPD SIM ANTI ICING SPD SIM Press ENTER key Set back to operation mode Press ESC to show operator screen Scroll Up ...

Page 53: ...lses for the distance calculate the total pulses for 1 km mi and put into GROUND SENSOR INPUT The first line of the Trip Summary toggles units between km mi and pulses each time it is accessed 14 14 14 14 How to set up or null min max outp How to set up or null min max outp How to set up or null min max outp How to set up or null min max outputs of a Conveyor valve uts of a Conveyor valve uts of a...

Page 54: ...ess ENTER to store the value and exit edit mode For CLOSED LOOP operation either pulses rev or flow min PROGRAM MODE SENSORS VALVES CONVEYOR SETUP VALVE SETTINGS ensure that correct pulses are put in Select AUTO NULL Press ENTER to select and ENTER again to start Once AUTO NULL stops it completes Note For very slow conveyors max RPM 100 the AUTO NULL may start twice to calculate correct max RPM va...

Page 55: ...Solid For Solid For Solid Pre Pre Pre Pre wet Operation wet Operation wet Operation wet Operation For An For An For An For Anti ti ti ti Icing Operation Icing Operation Icing Operation Icing Operation 1 Material Detection 2 Material Change 3 Low Liquid Pressure 4 Plow Indicator 5 Spare 6 P Float Indicator 7 Low Oil Indicator 8 Body Up Indicator 1 Left Boom 2 Liquid Change 3 Low Liquid Pressure 4 R...

Page 56: ...ump Dump Dump Dump body will not raise when loaded body will not raise when loaded body will not raise when loaded body will not raise when loaded Check pump flow and pressure Check port relief if installed Push override on coil or stroke limiter 4 4 4 4 Slow hydraulic function Slow hydraulic function Slow hydraulic function Slow hydraulic function Check pump flow and pressure Check return line fi...

Page 57: ...57 57 Bosch Rexroth Canada ı 03 10 2011 ı Revision 5 4 Check pump suction line for cavitation Notes ...

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