F1000T, F1000W System Start up & Calibration procedure Version Modified By Release notes Issue A Vijayakumar Creation 2010-04-20 USA Selma, TX 78154 www.dynapac.com Page: 1
Introduction This section documents the machine setup procedure & calibration sequence to be performed on the new pavers end of production line & also incase any of the devices like Propel Pumps, Motors, Propel Input devices changed out in the field or the propel controller gets new program. Assumptions: You have a good working knowledge of how the PLUS+1 Service Tool & Paver Hyd & electrical system works; Required Tools: 1. Have had Service Tool training (service tool experience) 2. Know how to connect the Service Tool 3. Program for the controllers & displays already downloaded as per Dynapac Software Download & Paver Setup _Version A.doc 4. Aware of how the Paver electrical & hydraulic system interact each other. 5. The hydraulic connections are correct per hydraulic design schematic 6. proper wiring techniques have been followed per Paver electrical schematic 1. Laptop with Sauer plus 1 Service Tool version 4.3 2. DYNAPAC Paver CAN CG 150 Cable D717951884 3. DYNAPAC Service Tool program D717951919.p1d Precaution before performing the below procedure: Perform the following procedure to checkout the vehicle prior to controller and engine start up. 1. Put Paver In The Air (vehicle on stands with the wheels/tracks free to move and off the ground) and check that it is properly supported to allow operation of the propel function. Make sure there is room around the machine. 2. If the Paver cannot be put in the air then need to have enough room all sides of Paver such that Paver can run in 1 st gear full speed for at least 2 minutes forward & 2 minutes reverse USA Selma, TX 78154 www.dynapac.com Page: 2
Paver Model Definition DYNAPAC F1000T & F1000W model pavers have the same program & the controller needs to be taught which model of the Paver is connected to it. Based on the model selection, the program will automatically choose its inputs & outputs it needs to control. Below procedure helps to set the Paver model, 1. Switch on the key Switch. Don t crank the engine 2. When the Paver is switched on first time after downloading the program then the Paver model need to be selected either using Left or Right console display. 3. Based on the Paver model (10 Track or 10 Wheel) using the scroll down buttons select the Paver model in the Display 4. Once the symbol is on the correct Paver model then press button showing OK 5. The display will ask for a password to change the Paver model. 6. Please enter the appropriate password by pressing the buttons in the Display. 7. If you are a authorized service technician to service the Dynapac Pavers then please contact the Dynapac team to get the proper password 8. If you enter the wrong password then the Paver model will not be selected & none of the functions that are controlled by the Propel controller will be functioning. 9. Once the correct password is entered the display will ask to REPOWER THE SYSTEM. Switch off the key switch & switch on again. 10. Now the Controller will know which type of Paver it is controlling & display (Right or Left) will show symbol on the Paver model previously selected. 11. Please verify that the Display is showing the correct model code selected previously Should there is any question or the system is not performing the way it suppose to be please contact DYNAPAC for further assistance. USA Selma, TX 78154 www.dynapac.com Page: 3
Paver Calibration The input devices & the output devices connected to the controller are not exactly having same manufacturing tolerances & control setups every time we buy or every time we change a new one in the field. In order to accept the defined variances on the input & output devices the controller will read the minimum & maximum values for each device connected to it. The procedure to teach the controller about the devices connected to it is called calibration & Calibration need to be done in one following cases (but not limited to) 1. End of production line of Pavers 2. Whenever new version of program is downloaded to the propel computer 3. When any of the input or output devices connected to the controller is changed out in the field. 4. Paver performance is not to the adequate levels. Input Devices, Pump Threshold & Max current calibration 1. Start the engine. 2. Select gear 1 using the gear selector switch on Left console. This will run the engine at 1800 rpm. All the devices should be calibrated at 1800 rpm of engine 3. Connect the laptop to CG150 Cable (D717 951884) & other end of the cable need to be connected to the CAN port on the DC Box 4. Make sure all the devices are connected to the CAN System by doing a File Scan System via the service tool program version 4.3. 5. Using service tool 4.3 go to File Open & browse D717951919.p1d (DYNAPAC Service tool program) & open in the service tool. This program shows all the default parameters set on the Controller & Displays. This program also has number of screens & some of them are used to do the calibration. 6. Go to Security Access Tab & click on the link to enable write access. Then enter 1234 as a value for the parameter & download into the controller. Now the controller allows write access & the calibration will be allowed to happen. Refer the pictures below to perform the Step 6. USA Selma, TX 78154 www.dynapac.com Page: 4
7. Once the write permission enabled go to MC50 Dual Path Tab under parameter functions & look for a page called Start Calibration. Click on the Start calibration page & that will open the calibration buttons. USA Selma, TX 78154 www.dynapac.com Page: 5
8. Press button called Start with Input Calibration. If the engine is already running in 1800 rpm & everything is okay to do the calibration a new button will appear on the screen called Proceed to Input Calibration. Click on the button & that should navigate to a new screen. Before pressing the Proceed button please make sure that all the input devices like Joystick, Steering wheel, Speed dial pot, Steering trim pot, and Steering position sensor in its neutral position. The new screen will look like as shown in below picture USA Selma, TX 78154 www.dynapac.com Page: 6
9. To calibrate the each input device please follow the below procedure The center position for each device is automatically calibrated. The max min & max positions should be calibrated using the below procedure Calibrate FNR Joystick (Track & Wheel Paver) LH & RH Console A. Move Joystick full forward and hold for 3 seconds until the desired value is captured. This value will automatically be entered on the screen. B. Repeat Step A for the reverse direction. C. The center position of the Joystick should already have been captured during the hyperlink to the Input Calibration Log Function page. This occurs because once the input calibration is started; the center position (neutral) value can be obtained as long as the Joystick is in the neutral position. D. When the Joystick is calibrated, the status will change to OK and turn green. E. Return the Joystick to neutral USA Selma, TX 78154 www.dynapac.com Page: 7
Calibrate Trim Steer POT (only on Track Paver) LH & RH Console Similar to calibrating joystick A. Turn the Trim Steer pot to the maximum position (full right) and hold for 3 seconds until the desired value is captured. B. Turn Trim Steer pot to the minimum position (full left) and hold for 3 seconds until the desired value is captured. C. Turn the Trim Steer pot to the middle position (usually around 5000) and hold for 3 seconds until the desired value is captured. D. When the Trim Steer is calibrated, the status will change to OK and turn green. Calibrate Steering Wheel (only on Track Paver) LH & RH Console A. Turn the Steering Wheel to the maximum position (full right) and hold for 3 seconds until the desired value is captured. B. Turn Steering wheel to the minimum position (full left) and hold for 3 seconds until the desired value is captured. C. Turn the Steering wheel to the middle position (usually around 5000) and hold for 3 seconds until the desired value is captured. D. When the steering wheel is calibrated, the status will change to OK and turn green. Calibrate Max Speed POT (Track & wheel Paver) LH & RH Console A. Move the Max Speed pot to maximum (full) command and hold for 3 seconds until desired value is captured. B. Move the Max Speed pot to minimum command and hold for 3 seconds until the desired value is captured. C. When the Max Speed is calibrated, the status will change to OK and turn green. Screen dump D. Return Max Speed pot to the minimum position Calibrate Steering Position sensors (Wheel Paver only) LH Console only Before starting the calibration make sure the FWA wheels are in straight position. A. Turn the Steering Wheel to the maximum position (full right) and hold for 3 seconds until the desired value is captured. B. Turn Steering wheel to the minimum position (full left) and hold for 3 seconds until the desired value is captured. USA Selma, TX 78154 www.dynapac.com Page: 8
C. Turn the Steering wheel to the middle position and hold for 3 seconds until the desired value is captured. D. When the steering wheel is calibrated, the status will change to OK and turn green. Once all the devices are calibrated the Input calibration page will look like below picture 10. Pump Threshold calibration Make sure FWA Switch is in OFF Condition (Wheel Paver Only) before doing the threshold calibration The pumps are required to be calibrated so that the controller can find the starting current required to barley move the machine. Once the Next Stage button is pressed in input calibration window a new window will open to capture the pump threshold currents. a. Move the Speed Dial POT to max position. b. Move the Joystick out of its neutral position & keep it full forward. c. Now the controller will automatically starts to apply the current to pumps to the move the machine barely forward & captures the current required to move in forward. d. Once forward direction is captured then the Controller will automatically puts current to pumps to move the machine barely reverse & captures the current required to move the Paver in reverse. USA Selma, TX 78154 www.dynapac.com Page: 9
e. Bring the joystick to neutral to complete the calibration. Once the values are captured & joystick is brought back to neutral the screen will look like the below picture, 11. Max Current Calibration : The controller will capture the maximum current that needs to put to the pumps to achieve the desired ground speed. Make sure the Paver is in 1 st gear (Engine 1800 RPM) before doing this calibration. a. Press Next stage if you still in the Threshold calibration page. It will navigate to the new page b. Keep the Speed dial pot to Max Position c. Move the joystick out of neutral to full forward position d. Hold the joystick in max position until the forward values are captured & turns Green with OK e. Bring the joystick to full reverse position. f. Hold the joystick in full reverse position until the reverse values are captured & turns Green with OK g. Bring the joystick to neutral position once all the values are captured & turned Green & OK h. The below picture shows how the screen will look after completing the max current calibration. USA Selma, TX 78154 www.dynapac.com Page: 10
With this all the calibration s are completed & the Paver is ready to do the propel function. If the calibration is not completed successfully or terminated in between due to various reasons then all three calibrations need to be repeated again until all the calibrations are completed. USA Selma, TX 78154 www.dynapac.com Page: 11