Tie Bar Inserter (TBI)
Powered Transition Adjuster (PTA) Controller
Operator's Manual
Version 2.0
01 Content of Chapter
This chapter gives a description of all electrical controls used on the Side Bar Inserter (SBI) controller and the Tie Bar Inserter/Powered Transition Adjuster (TBI/PTA) controller. The controls and screen of the Display Controller are also covered. Read this chapter thoroughly to familiarize yourself with all controls and operations. Pay particular attention to all safety statements!
02 Automatic Side Bar Inserter (SBI) Controller
IDBI-0787
The G+ Automatic Side Bar Inserter (SBI) controller can be used as a stand-alone controller to control the insertion of tie bars into one side of the slab, or it can be connected to a CAN network to work in conjunction with other controllers. When the controller is used as a stand-alone unit, the distance measurement for insertion of bars is controlled by an encoder running on the track, or a pulse pickup unit in a track motor.
When connected to the CAN network, the display controller (see later) must be connected to the CAN.
The display controller is used to program the bar spacing, including skipped spaces. The distance measurement for insertion of bars is provided by an encoder running on one or two tracks, or a pulse pickup unit in one or two track motors. A proxi switch or a manual switch can be connected and used to
interrupt the spacing (see Operation of the CAN System later).
Description of the various switches and lights follows.
Power Switch: Used to turn the controller on or off. Placing the switch in the "Off" position turns the controller off. Placing the switch in the "On" position turns the cotroller on. Placing the switch in the "Off"
position will not turn the CAN power off.
Power Indicator Lamp: Will illuminate when power is supplied to the controller.
Set Distance Switch: Used to set the bar spacing distance when the controller is used as a stand-alone system. With the switch "Off" and the power switch
"On", stop the machine travel. Mark a spot on a track frame and a corresponding spot on the ground. Place a mark on the ground the desired spacing distance from the first mark. Place the set distance switch in the "On" position and move the machine forward until the mark on the track frame is even with the second mark. Stop the machine travel and place the set distance switch in the "Off" position. The computer will store this distance and will activate the insert cycle each time the machine has traveled the stored distance, provided the auto/manual switch is in "Auto"
and the Arm Side-Bar system switch has been toggled.
Note: The Set Distance switch will have no affect on the spacing distance when operating on the CAN network.
Auto/Manual Switch: Sets the inserter for manual or automatic operation. When the switch is in the
"Manual" position, the Inserter jog switch is used to move the inserter. When the switch is in the "Auto"
position, the inserter will automatically insert a bar at each preset distance spacing. The light below the Arm Side-Bar system switch will flash when the controller is in "Manual".
Inserter Jog Switch: Used to manually insert the bars. Move the switch in the Insert direction ( ) to push bars into the slab and move the switch in the Retract direction ( ) to withdraw the inserter.
Drive Indicator Lights: Illuminate when the inserter is activated to move in the corresponding direction.
Proxi Switch Indicator Lights: Illuminate when the corresponding proxi switch is activated.
Do not "arm" the system prior to placing a bar in the inserter tray. Injury could occur if the inserter activates while placing a bar in the tray. Keep hands and feet away from moving parts once the system is "armed".
0225Arm Side-Bar System Switch: Used to activate the controller prior to each insertion cycle. After the insertion cycle is complete and a bar has been placed in the inserter tray, toggle the switch (either direction) to "arm" the system for insertion. If the switch is not toggled, the system will not insert the bar.
Armed Lamp: The indicator lamp will flash to indicate that the side-bar system has not been "armed". The indicator lamp will remain illuminated to indicate that the side-bar system has been "armed". If the light is flashing, the system will not insert the bar. The indicator lamp will also flash when the controller is in
"Manual".
Vibrator Switch: Used to manually control the vibrator on the inserter. Push up on the switch to activate the vibrator. When operating in automatic, the vibrator operation is controlled by the inserter system.
IDBI-0455
The side bar inserter is equipped with two adjustable proximity (proxi) switches. One signals the controller when the inserter is retracted and the other signals when the bar is fully inserted. The position of the insert proxi switch and the flag on the insert tube determines the depth of insertion into the side of the slab.
Operation of System: To operate the system automatically, connect an encoder or pulse pickup to the Encoder Input plug (#1) on the side of the controller. To set the bar spacing distance, mark a spot on a track frame and a corresponding spot on the ground. Place a mark on the ground the desired bar spacing distance from the first mark. Place the
set distance switch in the "On" position and move the machine forward until the mark on the track frame is even with the second mark. Stop the machine travel and place the set distance switch in the "Off" position.
The computer will store this distance and will activate the insert cycle each time the machine has traveled the stored distance, provided the Auto/Manual switch is in "Auto" and the Arm Side-Bar system switch has been toggled.
Do not "arm" the system prior to placing a bar in the inserter tray. Injury could occur if the inserter activates while placing a bar in the tray. Keep hands and feet away from moving parts once the system is "armed".
0225Hold the Inserter jog switch in the Retract drive ( ) position until the inserter is full retracted. The retract proxi lamp should illuminate. Place a bar in the holder (see the Side Bar Inserter (SBI) Operation section for adjustment procedures). Place the Auto/
Manual switch in the "Auto" position. The armed lamp should flash. Toggle the Arm Inserter switch either direction to "arm" (prepare) the system to insert the bar. The armed lamp should stop flashing and remain illuminated. When the machine has traveled the preset distance, the inserter will automatically activate to push the bar into the side of the fresh concrete.
The vibrator will also activate as the bar is inserted.
When the extend proxi lamp illuminates, the bar is at the correct depth and the inserter will automatically retract until the retract proxi lamp illuminates and the inserter stops. The extend and retract drive lamps will illuminate when the inserter is moving in the corresponding direction. Repeat the process by placing another bar in the inserter and toggling the Arm Inserter switch.
The system can also be activated by connecting a proxi switch to the Trigger Proxi plug (#5) on the side of the controller box (with no encoder or pulse pickup connected). To use the proxi switch, a metal object must be positioned at the insertion location (for example, on the ground). When the proxi switch passes over the metal object, the inserter will activate and insert the bar into the side of the fresh concrete.
The system can also be operated manually by connecting a manual (toggle) switch to the Trigger Proxi plug (#5) on the side of the controller box (with no encoder or pulse pickup connected). Each time a bar is to be inserted, toggle the switch.
03 Automatic Tie Bar Inserter/Powered Transition Adjuster (TBI/PTA) Controller
(White numbers are not on actual control box) IDBI-0705
The G+ Tie Bar Inserter/Powered Transition Adjuster (TBI/PTA) controller can be used as a stand-alone controller to control the insertion of tie bars into the center of the slab, or it can be connected to a CAN network to work in conjunction with other controllers. To work as a PTA controller, the unit must be connected to the CAN network and the display controller (see later). When the controller is used as a stand-alone unit to insert tie bars, the distance measurement for insertion of bars is controlled by an encoder running on the track, or a pulse pickup unit in a track motor (see Operation of System later).
When connected to the CAN network, the display controller (see later) must be connected to the CAN.
The display controller is used to program the bar spacing, including skipped spaces. It is also used to control the elevation of the PTA(s). The distance measurement for insertion of bars is provided by an encoder running on one or two tracks, or a pulse pickup unit in one or two track motors. A proxi switch or a manual switch can be connected and used to interrupt the spacing (see Operation of the CAN System later).
Description of the various switches and lights follows.
Note: The number in () corresponds to the number on the photo. The numbers are not on the actual control box.
Power Indicator Lamp: (1) Will illuminate when power is supplied to the controller.
Power Switch: (2) Used to turn the controller on or off. Placing the switch in the "O" position turns the controller off. Placing the switch in the "I" position turns the cotroller on. Placing the switch in the off position will not turn the CAN power off.
Drive Indicator Lights: (3) Illuminate when the inserter is activated to move in the corresponding direction, using either the jog switch, or the automatic controls.
Note: If both lamps are flashing, it indicates a smart (insertion) cylinder out of range fault.
Inserter Jog Switch: (4) Used to manually insert the bars. Move the switch in the (down) direction to push bars into the slab and move the switch in the (up) direction to withdraw the inserter.
Automatic Indicator Lamp: (5) Indicates when the controller is in "Auto". When the auto/manual switch is in the "Manual" position, the lamp will be off. When the switch is placed in the "Auto" position, the lamp will illuminate steadily. If the switch is in the "Auto"
position when power is supplied to the controller, the lamp will be out. It will be necessary to place the switch in the "Manual" position and then back in
"Auto".
Auto/Manual Switch: (6) Sets the inserter for manual or automatic operation. When the switch is in the
"Manual" position, the jog switch is used to move the inserter. When the switch is in the "Auto" position, the inserter will automatically insert a bar at each preset distance spacing.
Armed Lamp: (7) The indicator lamp will flash to indicate that the tie-bar system has not been "armed".
When the tie-bar system has been "armed", the indicator lamp will illuminate steadily. If the light is flashing, the system will not insert the bar. The indicator lamp will also flash when the controller is in
"Manual".
Note: The Armed lamp is only active when the controller is operating a frame mounted tie-bar inserter. The lamp will be out when a 5400 bar inserter is being used.
The lamp is also used to indicate the smart (insertion)
cylinder setup mode. To enter the setup mode, turn the power off. Hold the "Arm" switch (8) in the "on"
position and turn the power switch "on". Hold the Arm switch until the Arm Lamp (7) flashes 5 times, then a long pause, followed by 5 flashes (approximately 4 seconds). When in the setup mode, the UP lamp will flash. Use the inserter jog switch (4) to move the inserter to the up position. Continue to hold the switch in the (up) position until the up lamp goes out and the down lamp begins to flash (approximately 15 seconds). Use the inserter jog switch to move the inserter to the down position. Continue to hold the switch in the (down) position until the down lamp goes out (approximately 15 seconds).
Do not "arm" the system prior to placing a bar in the inserter forks. Injury could occur if the inserter activates while placing a bar in the tray. Keep hands and feet away from moving parts once the system is "armed".
0225Arm Tie-Bar System Switch: (8) Used to activate the controller prior to each insertion cycle. After the insertion cycle is complete and a bar has been placed in the inserter forks, toggle the switch (either direction) to "arm" the system for insertion. If the switch is not toggled, the system will not insert the bar.
Note: The Arm switch is only active when the controller is operating a frame mounted tie-bar inserter. The switch is inactive when a 5400 bar inserter is being used, except for initial setup (see previous).
Set Spacing Switch: (9) Used to set the bar spacing distance when the controller is used as a stand-alone system, using ecoders or pulse pickups in the track drive motors. With the switch "Off" and the power switch "On", stop the machine travel. Mark a spot on a track frame and a corresponding spot on the ground.
Place a mark on the ground the desired spacing distance from the first mark. Place the set distance switch in the "On" position and move the machine forward until the mark on the track frame is even with the second mark. Stop the machine travel and place the set distance switch in the "Off" position. The computer will store this distance and will activate the insert cycle each time the machine has traveled the stored distance, provided the auto/manual switch is in
"Auto".
Note: The set distance switch will have no affect on the spacing distance when operating on the CAN network.
Keep clear of the moving chain conveyor. Injury could occur if caught in the conveyor.
0226Chain Conveyor Switch: (10) Used to advance the tie bar chain conveyor on the 5400 tie-bar inserter.
Toggling the switch in the "Advance" direction will cause the conveyor to advance one bar slot. To advance the conveyor farther, release and then toggle the switch again. Repeat as necessary.
Conveyor Stop Proxi Switch Indicator Light: (11) Illuminates when the chain conveyor has advanced far enough to load a bar in the inserter. When the inserter activates and places a bar, the chain conveyor will automatically advance, placing the next bar in position. The conveyor will stop when the proxi switch is activated.
IDBI-0706
CAN Indicator Light: The light on the side of the box, next to the CAN connection plug, will flash to indicate that the controller is connected to the CAN network.
When the inserter is being controlled through the CAN network, the light will flash at a rate of "on for 0.5 second, off for 1.0 second, repeat". If the light does not flash as indicated, check all electrical connections.
IDBI-0707
When an encoder is connected, the encoder input light will flash at a rate of "two 0.25 second (quick) flashes, followed by off for 3 seconds, repeat". If the light does not flash as indicated, check all electrical connections.
Operation of System: To operate the system automatically without the display controller, connect an encoder or pulse pickup to the Encoder Input plug (#1) on the side of the controller. To set the bar spacing distance, mark a spot on a track frame and a corresponding spot on the ground. Place a mark on the ground the desired bar spacing distance from the first mark. Place the set distance switch in the "On"
position and move the machine forward until the mark on the track frame is even with the second mark. Stop the machine travel and place the set distance switch in the "Off" position. The computer will store this distance and will activate the insert cycle each time the machine has traveled the stored distance, provided the Auto/Manual switch is in "Auto".
The 5400 TBI is operated automatically by the controller and may move unexpectedly. Keep hands and feet away from moving parts.
02275400 Style Inserter: It will be necessary to "teach"
the controller the electrical up and the electrical down positions of the inserter. Adjust the mechanical down stop before setting the electrical down position (see the 5400 Style Tie Bar Inserter (TBI) Operation section for adjustment procedures). Place the power switch in the "off" position. Hold the Arm switch in the "Arm" (upper) position and turn the power switch
"On". Continue to hold the Arm switch until the arm light, and the drive up light, begin to flash. Release the arm switch and hold the inserter jog switch in the "up" position. The inserter should move upward (retract). Continue to hold the switch "up" until the inserter is completely up (retracted) and the up light stops flashing and goes out (will take approximately 15 seconds). The down light should start flashing.
Hold the inserter jog switch in the "down" position until the inserter is fully down (inserted) and the down light stops flashing and goes out (will take approximately 15 seconds). The up and down electrical positions are now set. If the mechanical down position is changed, the electrical up and down settings must be reset following the same procedure.
Hold the Inserter jog switch in the Drive Up ( ) position until the inserter is full retracted. Fill each spot on the top of the chain conveyor with the desired size bars. Place bars in the magazine above the chain conveyor. Activate the Chain Conveyor switch to
advance the conveyor until the first bar has dropped into position in the inserter. Place the Auto/Manual switch in the "Auto" position. When the machine has traveled the preset distance, the inserter will automatically activate to push the bar into the fresh concrete. When the bar is at the correct depth, the inserter will automatically retract until the inserter is completely up. The Drive Up, or the Drive Down lamp will illuminate when the inserter is moving in the corresponding direction. When the inserter is fully retracted, the chain conveyor will automatically advance to place the next bar in the inserter. The Conveyor Stop proxi lamp will illuminate to indicate that the conveyor has advanced and stopped.
Frame Mounted Inserter: It will be necessary to "teach" the controller the electrical up and the electrical down positions of the frame mounted bar inserter. Adjust the mechanical down stop before setting the electrical down position (see the Frame Mounted Tie Bar Inserter (TBI) Operation section for adjustment procedures). Place the power switch in the
"off" position. Hold the Arm switch in the "Arm" (upper) position and turn the power switch "On". Continue to hold the Arm switch until the arm light, and the drive up light, begin to flash. Release the arm switch and hold the inserter jog switch in the "up" position. The inserter should move upward (retract). Continue to hold the switch "up" until the inserter is completely up (retracted) and the up light stops flashing and goes out (will take approximately 15 seconds). The down light should start flashing. Hold the inserter jog switch in the "down" position until the inserter is fully down (inserted) and the down light stops flashing and goes out (will take approximately 15 seconds). The up and down electrical positions are now set. If the mechanical down position is changed, the electrical up and down settings must be reset following the same procedure.
Do not "arm" the system prior to placing a bar in the inserter forks. Injury could occur if the inserter activates while placing a bar in the tray. Keep hands and feet away from moving parts once the system is "armed".
0225Hold the Inserter jog switch in the Drive Up ( ) position until the inserter is full retracted. Position a bar in the notches at the lower end of the insertion forks. Toggle the Arm switch to arm the system to insert the bar. Place the Auto/Manual switch in the
"Auto" position. When the machine has traveled the preset distance, the inserter will automatically activate to push the bar into the fresh concrete. When the bar
is at the correct depth, the inserter will automatically retract until the inserter is completely up. The Drive Up, or the Drive Down lamp will illuminate when the inserter is moving in the corresponding direction.
When the inserter is fully retracted, place the next bar in the notches and toggle the Arm switch. If the Arm switch is not toggled, the bar will not be inserted.
Either system can also be activated by connecting a proxi switch to the Trigger Proxi plug (#5) on the side of the controller box (with no encoder or pulse pickup connected). To use the proxi switch, a metal object must be positioned at the insertion location (for example, on the ground). When the proxi switch passes over the metal object, the inserter will activate and insert the bar into the side of the fresh concrete.
The system can also be operated manually by connecting a manual (toggle) switch to the Trigger Proxi plug (#5) on the side of the controller box (with no encoder or pulse pickup connected). Each time a bar is to be inserted, toggle the switch.
05 Display Controller Screens Introduction
The Side Bar Inserter (SBI) controller(s) and/or the Tie Bar Inserter/Powered Transition Adjuster (TBI/PTA) controller(s) can be connected to a CAN network.
A Display Controller is also connected to the CAN network and is used to control the operations of the SBI(s) and/or TBI(s). From the display interface, the operator can configure the software to insert side bars and tie bars that meet the particular job specifications.
The operator may also use the display interface to set PTA heights and transitions.
Note: Some displays on the controller are for the Independant Dowel Bar Inserter (IDBI) attachment and may not pertain to the SBI/TBI/PTA.
Disregard displays that do not pertain.
028-0491
Navigation buttons: The up ( ), down ( ), right ( ), or left ( ) buttons are used to move the red selection cursor on the display screen to a desired menu item. The up ( ) or down ( ) buttons are also used to increase or decrease certain values in data entry displays and to access upper and lower level displays.
If an additional display is available from a certain screen, an up ( ) or down ( ) arrow will appear on the screen. Pressing the left ( ) and right( ) navigation buttons simultaneously will toggle the display screen between the two languages that are loaded into the system.
OK button: The OK button is used to open a selected menu item or to store values in data entry displays.
Escape button (ESC): The escape button (ESC) is used to return to upper level menus or to return values to their previous settings in data entry displays.
Numbered buttons (1-8): The numbered buttons are used to directly open a numbered menu item, or to select a data entry box in a data entry display.
Edit Value
= Backspace
MIDBI-007
= +/-
= 9
= 0
10.00 200.00
VALUE OUT OF RANGE Current Value
New Value
. 0 20.00
MIDBI-007
When a number box appears on a screen, the value can be changed by pressing the corresponding numbered button. When the button is pressed, a pop- up screen will appear to allow the value to be changed.
The top line will indicate the current value setting.
Use the number buttons to enter the corresponding numbers 1-8. Use the down ( ) arrow button to insert
#9 and the up ( ) arrow button to enter #0. Use the right ( ) arrow to backspace and the left ( ) arrow to change between a positive (+) and negative (-) entry.
The value entered will have 2 digits to the right of the decimal point. If a whole number is to be entered, it will be necessary to enter 2 zeros (0) after entering the number. To return to the original screen without changing the setting, press the ESC button. If the new value entered is correct, press the OK button to store the value and return to the original screen.
If a question mark (?) appears in the upper right corner of a display, it indicates that a "help" screen is available, relating to the current display screen. Press the OK button to access the help screen. Press the ESC button to return to the previous display.
Main Menu
Run Menu MIDBI-069
MIDBI-069
When power is first supplied to the controller, the main menu display appears on the screen. The various sub-menus available are the Run menu (#1), the Test menu (#2), the Setup menu (#3), the Active Fault menu (#4), the Screen Setup menu (#5), the PTA menu (#6), the About menu (#7) and the Help menu (#8). Press the navigation buttons to move the red selection cursor to the desired menu icon. The title of the selected menu icon will appear in the status bar at the bottom of the screen. Press the OK button to enter the display screen. If a numbered button is pressed, the display will go directly to the corresponding screen.
Below is a brief description of the sub-menus available from the main menu:
Run Menu
169
MIDBI-070
2
Count Down
13.12
15.00
4 5 1 3
15.00 15.00
15.00 15.00
2453 ft 8.5 ft/min
!
MIDBI-070
From the Main menu display, press the navigation buttons to move the red selection cursor to the Run menu icon (#1). Press the OK button to enter the Run display screen (or press the number 1 button to bypass cursor navigation and directly enter the Run display screen). Press the escape button (ESC) to return to the Main menu.
Up to five dowel bar space (transverse joint) distances are displayed at the top of the screen in the order in which they were entered in the Setup Menu. The current space is shown by a green box surrounding the space box. This box moves consecutively with the current space #. The "Count Down" displays the remaining distance that the paver must travel until the next dowel bar location. When the count down value reaches zero the "Count Down" display will reset to the next spacing.
Note: If a space has 0.00 entered, the box will be "grayed" out. The current space green box will skip that space and proceed to the next space with a value entered.
120The DBI FIRE lamp will turn green when the paver reaches each space location as indicated by the dowel bar space (transverse joint) distances. When the lamp turns green, the TBI beginning spacing distance is reset to start at "0" at that point.
121If a proxi switch, or a manual (toggle) switch, is
connected to the Proxi Trigger plug on the display controller, the indicator will turn green and will remain green as long as the proxi or manual switch is activated.
151The spray marker indicator will turn green when the spray marker is activated. The marker will activate after the DBI FIRE lamp has illuminated and the machine has travelled the offset distance specified in the Setup manu.
150The TBI FIRE indicator will turn green every time a TBI is activated to insert a tie bar into the fresh concrete.
Which TBI(s) is (are) activated is indicated by the number on the icon.
149The SBI FIRE indicator will turn green every time the SBI is activated to insert a tie bar into the side of the fresh concrete.Which SBI(s) is (are) activated is indicated by the number on the icon.
152
The spray bar indicator will turn green every time the spray bar is activated to spray a mist of water on the fresh concrete.
Note: Normally a burlap drag is attached to the rear of the machine and the water mist is sprayed on it.
148The fault icon will turn yellow and will flash indicating a fault in the system. Return to the Main menu and use the navigation buttons to move the red selection cursor to the Fault menu icon (#4). Press the OK button to enter the display screen and view the fault. If the number 4 button is pressed, the display will go directly to the Fault screen.
010The distance traveled by the paver, from the last time the distance was cleared, is displayed with the current units of measure. This distance is the calibrated distance calculated by the computer using the track encoder, or pulse pickup, average and calibration factor.
126The paver speed is shown in either FT/MIN (feet per minute) or M/MIN (meters per minute). This value is the current speed of the paver calculated by the computer using the track encoder average.
086
Start Transition 200.00 ft MIDBI-181
in
in in in ft
1 2 3 4 5
1.50 3.00 0.00 0.00 200.00
0 0.00 0.00 0.00 in
8
+ + +
0.00+
MIDBI-181
From the Run screen, press the down ( ) navigation button to access the PTA Status screen. Use the Status screen to set the target crown for a PTA and set the transition distance. Press the number 1, 2, 3 or 4 buttons to enter the "edit values" display for the corresponding PTA. Enter the target crown desired.
Note: If a PTA is not enabled in the PTA Setup screen (see later), the corresponding PTA box will be "grayed" out and not accessable.
Press the number 5 button to enter the "edit values" display for the transition distance. Enter the appropriate transition length. If the transition is stopped at mid point (computer turned off), the transition distance must be reset to the remaining distance prior to completing the transition. If the distance is not reset to the remaining distance, the balance of the crown change will occur over the original distance entered.
Make certain that the PTA Run mode is set to
"Automatic" in the PTA Setup screen (see later), and that the "A" box in the lower right corner is illuminated
"green". At the beginning point of the transition, press the number 8 button to start the transition. The "T"
box in the lower right corner will illuminate "green"
to indicate that the transtion is active. The Start Transition indication on the lower line will change to
"Cancel Transiton". Press the number 8 button to cancel the transition.
When the transition is active, the distance on the lower line will count down, indicating the remaining transition distance. The PTA indicators will show the current crown height for each PTA. When the PTA reachs the preset crown height, the distance on the lower line should read "0.00". The gear icon on the lower line will rotate as the paver is moving and will stop when the paver stops. This is a good indication that signals are being received from the encoders/pulse pickups.
Pressing the up ( ) navigation button will return the display to the Run menu. Pressing the ESC button will return the display to the PTA menu (see description later).
Test Menu
165Test Menu
MIDBI-072
Controller Power
MIDBI-072
From the Main menu display, press the navigation buttons to move the red selection cursor to the Test menu icon (#2). Press the OK button to enter the Test display screen (or press the number 2 button to bypass cursor navigation and directly enter the Test display screen). Press the escape button (ESC) to return to the Main menu.
The Test menu is used to access the display screens for checking the voltages of the various system controllers (#1), the encoder signals and the various distance information (#2), the various switch input signals (#3) and the various output signals (#4).
Press the navigation buttons to move the red selection cursor to the desired Test menu icon. The title of the selected icon will appear in the status bar at the bottom of the screen. Press the OK button to enter the display screen (or press a numbered button to bypass cursor navigation and directly enter the screen). Press the escape button (ESC) to return to the Test menu.
Below is a description of each of the test displays:
Controller power
170
MIDBI-073
Controller Power
11.95 12.04
MIDBI-073
The controller power display shows the battery voltage supplied to each of the computer controllers. From top to bottom is the battery voltage supplied to the screen (display) and the main controller. The voltage available to each controller should range from 9.0 to 16.0 volts. 12 to 13 volts is the normal voltage supplied.
Distance display
171
MIDBI-176
Distance Encoder 1
24066
Encoder 2
Pulses / ft Calibration
Factor
Average
Pulses / m
25040 24553
24.46 ft 8.5 ft/min
1.000
1200 1.000 3937
MIDBI-176
Indicates the status of all distance related devices.
The top line of boxes indicate the encoder signals during operation. A green box will indicate when the encoder is turned “on” in the setup menu. The average box indicates the numerical average if both encoders are in operation.
Distance traveled is monitored in the left center box and shows the total distance that the machine has travel since last cleared. The total distance is cleared to zero in the setup menu (see later). The right center box monitors the current travel speed of the machine.
Note: The distance traveled and travel speed will be displayed in feet, or meters, depending on the units selection in the Machine Setup screen (see later).
The calibration factor and pulses/foot or meter is set when the encoders are calibrated during initial setup (see the setup menu for more information).
Input/Output Status
075
MIDBI-174
Input/Output Status
TBI 1 Inputs TBI 1 Outputs
1
Insert Time
1500 ms Sensor
0.00 V 0.00 V
MIDBI-175
Input/Output Status
TBI 1 Inputs TBI 1 Outputs
1
Insert Time
1500 ms Sensor
0.00 V 0.00 V
MIDBI-174 & 175
The input/output test display for either the frame mounted inserter (FMI) or the 5400 TBI is used to test the input connection between the various remote switches and the controller and the output connection
to the valves. There are four screens for TBI inputs.
The number at the upper right, or in the description, indicates which TBI is being displayed. The order number of each inserter can be set in the Tech screen.
It will be necessary to contact GOMACO for the access number required to enter the Tech screen. The type of inserter will automatically be determined when the control slave is connected to the CAN network.
The display screen icons are simular. Where different, it will be noted. Use the down ( ) or up ( ) navigation buttons to scroll through the various displays. The description of the icons follow;
Input Icons
122 & 123
The A/M (auto/manual) status indicator will be gray with a line under the "M" when the system is in the Manual mode. The indicator will turn green and the line will be under the "A" when the system is in the Auto mode..
153The set distance icon will be gray with the Set
Distance switch in the "Off" position. The icon will turn green when the switch is placed in the "On" position.
154(5400 only) The chain conveyor icon will be gray when the Chain Conveyor jog switch is in the center position. The icon will turn green when the jog switch is moved either direction from center.
Note: The chain conveyor will only move in the forward direction irregardless of the direction the switch is moved.
161(FBI only) The arm icon will be gray when the Arm Side-Bar System jog switch is in the center position.
The icon will turn green when the switch is moved either direction from center.
155 & 156
The inserter up/down icons will be gray when the
Inserter jog switch is in the center position. The down icon will turn green when the switch is moved in the down direction, and the up icon will turn green when the switch is moved in the up direction.
157(5400 only) The chain conveyor proxi icon will be gray when the chain conveyor is moving to position a bar. The icon will turn green when the proxi switch is activated and the conveyor will stop.
158 & 159
The inserter down icon (↓) will turn green when the down proxi is activated on earlier bar inserters, or when the current inserter is in the "taught" down position. The inserter up icon (↑) will turn green when the up proxi is activated on earlier bar inserters, or when the current inserter is in the "taught" up position.
Both proxies will be gray when the inserter is in between positions.
160The fire-by-proxi icon will be gray if nothing is connected to the Trigger Proxi plug (# 5), or if a proxi switch, or manual switch is connected but not activated. If a proxi switch, or manual switch, is connected, the icon will turn green when the switch is activated.
Output Icons
155 & 156
The inserter up/down icons will be gray when there is no up or down drive signal to the inserter valve. The down icon will turn green when a down drive signal is sent to the valve, and the up icon will turn green when an up drive signal is sent to the valve.
154(5400 only) The chain conveyor icon will be gray when there is no drive signal to the drive motor valve.
The icon will turn green when a drive signal is sent to the drive motor valve.
161(FMI only) The arm icon will be gray when the Arm Side-Bar System is not armed. The icon will turn green when the system is armed by moving the jog switch either direction from center.
Note: There are a total of 7 Input/Output Status screens. Screens 1, 2, 3 and 4 are for the corresponding TBI's. Screens 5 and 6 are for the SBI's. Screen 7 is the master input/output and displays the number of implants for each inserter.
MIDBI-076
Input/Output Status
SBI 2 Inputs SBI 2 Outputs
Insert Time 1200 ms
6
MIDBI-076
The input/output test display for the SBI is used to test the input connection between the various remote switches and the controller and the output connection to the valves. There are two screens for SBI inputs.
The number at the upper right, or in the description, indicates which SBI is being displayed. Use the down ( ) or up ( ) navigation buttons to scroll through the various displays. The description of the icons follow;
Input Icons
123The A/M icon will be gray when the Auto/Manual switch on the corresponding SBI control box is in the
"Manual" position. The icon will turn green when the switch is placed in the "Auto" position.
153The set distance icon will be gray with the Set
Distance switch in the "Off" position. The icon will turn green when the switch is placed in the "On" position.
161The arm icon will be gray when the Arm Side-Bar System jog switch is in the center position. The icon will turn green when the switch is moved either direction from center.
155 & 156
The inserter retract/extend icons will be gray when the Inserter jog switch is in the center position. The retract icon will turn green when the switch is moved in the retract direction, and the extend icon will turn green when the switch is moved in the extend direction.
162The vibrator icon will be gray when the Vibrator Manual jog switch is in the center position. The icon will turn green when the jog switch is moved either direction from center.
158 & 159
The inserter retract proxi icon (↓) will be gray when the inserter is in the extended (in) position and will turn green when the inserter is in the retracted position.
The inserter extend proxi icon (↑) will be gray when the inserter is in retracted (out) position and will turn green when the inserter is in the extended (in) position. Both proxies will be gray when the inserter is in between positions.
160The fire-by-proxi icon will be gray if nothing is connected to the Trigger Proxi plug (# 5), or if a proxi switch, or manual switch is connected but not activated. If a proxi switch, or manual switch, is connected, the icon will turn green when the switch is activated.
Output Icons
155 & 156
The inserter retract (↓)/extend (↑) icons will be gray when there is no retract or extend drive signal to the
inserter valve. The retract icon will turn green when a retract drive signal is sent to the valve, and the extend icon will turn green when an extend drive signal is sent to the valve.
162The vibrator icon will be gray when there is no drive signal to the vibrator valve. The icon will turn green when a drive signal is sent to the valve.
161The arm icon will be gray when the Arm Side-Bar System is not armed. The icon will turn green when the system is armed by moving the jog switch either direction from center.
Note: There are a total of 7 Input/Output Status screens. Screens 1, 2, 3 and 4 are for the corresponding TBI's. Screens 5 and 6 are for the SBI's. Screen 7 (see next) is the master input/
output and displays the number of implants for each inserter.
MIDBI-077
Input/Output Status Master Inputs
Master Outputs
7
TBI 1 TBI 2 TBI 3 TBI 4 SBI 1 SBI 2
Fire# # Plants
54 54
46 43
0
0 0 0
231 231
229 194
MIDBI-077
The Master input/output test display, on the left side of the display, is used to test the input connection between the various switches connected to the controller and the controller, and the output
connections to the devices connected to the controller.
On the right side of the display is a record of the number of Fire (implant) signals that have been sent to the various devices and the number of actual Plants (insertions). In most cases, the number of Fire signals and actual Plants should be the same. If the number of Fire signals is greater than the number of Plants, it may indicate that the inserter did not activate for some reason. For example, if the Arm switch had not been activated on the SBI when a Fire signal was sent, the
inserter will not activate and there will not be a Plant recorded. The description of the icons follow;
Input Icons
163The Reset icon will be gray when the Reset switch is in the off (down) position. The icon will turn green when the switch is moved in the reset (up) direction.
164The proxi icon will be gray if nothing is connected to the Aux I/O plug (# 3), or if a proxi switch, or manual switch is connected but not activated. If a proxi switch, or manual switch, is connected, the icon will turn green when the switch is activated.
Output Icons
151The spray marker icon will be gray when there is no drive signal to the marker solenoid. The icon will turn green when a drive signal is sent to the marker solenoid.
152The water spray bar icon will be gray when there is no drive signal to the solenoid valve. The icon will turn green when a drive signal is sent to the solenoid valve.
Output signals
076
MIDBI-078
Output Test Fault Lamp
Paint Marker
TBI 4 TBI 3 TBI 2 TBI 1
SBI 2 SBI 1
Spraybar
MIDBI-078
The output test display is used verify that the controller is sending output signals to the various functions. To operate the test, use the arrow buttons to select the desired item to test and then depress the OK button.
When the function is activated, the indicator LED for the appropriate function on the display should illuminate and the corresponding function should operate. If the indicator LED does not illuminate, it indicates a problem in the system that must be corrected.
Setup Menu
166
MIDBI-079
Machine Setup Setup Menu
MIDIB-079
From the main menu display, press the navigation buttons to move the red selection cursor to the Setup menu icon (#3). Press the OK button to enter the Setup display screen (or press the number 3 button to bypass cursor navigation and directly enter the Setup display screen). Press the escape button (ESC) to return to the Main menu.
The Setup menu is used to set parameters for machine setup (#1), options (#2), dowel bar spacings (#3), tie bar spacings (#4), side bar spacings (#5) and distance setup (#6). The padlock icon (#7) is used to access a password entry screen.
Press the navigation buttons to move the red selection cursor to the desired Setup menu icon. The title of the selected icon will appear in the status bar at the bottom of the screen. Press the OK button to enter the display screen (or press a numbered button to bypass cursor navigation and directly enter the screen). Press the escape button (ESC) to return to the Setup menu.
Below is a description of each of the Setup displays:
Machine setup
172 Units
MIDBI-080
Encoder 2
1
English Machine Setup
DBI Fire Mode
MIDBI-080
English/metric section: Press the number 1 button to select the English/metric units box. Use the up ( ) or down ( ) arrow buttons to toggle between the English and metric choices. The units mode is used to designate the numerical system used in the distance measurements. Conversion of any existing measurements is automatic when changing from one numeric system to the other. To return to the original setting, press the ESC button. Press the OK button to store the new value.
DBI Fire Mode: Press the number 2 button to select the DBI Fire Mode box. Use the up ( ) or down ( ) arrow buttons to toggle between the choices. To return to the original setting, press the ESC button.
Press the OK button to store the new value. The DBI Fire signal is used to reset the TBI beginning spacing distance starting point to "0".
Select the Encoder mode if the TBI/SBI is being fired by distance measurements using the track mounted encoders, or pulse pickup units in the track motors.
The encoders, or pulse pickups, will need to be calibrated before use in the Distance Setup menu.
Select the Proxi Switch mode if the TBI/SBI is being fired by the remote mounted proxi switch, or by manual switch. If the proxi switch is connected, it is activated by passing over a metal object. For example, a metal object may be placed at each joint in an adjoining slab for a more accurate measurement of the joint spacing.
If the manual switch is connected, it is activated by moving it either direction from center.
Select the Encoder or Proxi mode if both methods are to be used. By using both modes, the system will respond to the first signal received. For example, if the system is being operated by the encoder and the spacing count needs to be reset, the proxi can be activated by passing over a metal object. The system then would reset and the encoder would continue to control the system until the proxi is activated again.
Instead of using the proxi to reset the system at every joint, a metal object could be positioned at every tenth joint (for example).
Options
078
MIDBI-081
5 3 6
2 1 Options
Paint Marker
Seconds Time On
Spraybar
Time On
ft
Offset Distance Off
1.00 2.50
36.00 10.00
7
Seconds
Inches MIDBI-081
Spraybar, Time On, Distance Off: The water spray bar system is mounted on the rear pan and is used to wet the burlap that is drug on the finished slab.
This system can be toggled on or off by depressing button #1 and then using the up ( ) or down ( ) arrow buttons to toggle the system on (check mark in box) or off (no check mark in box). To return to the original setting, press the ESC button. Press the OK button to store the new value. The computer controls the solenoid used to control the flow of water to the water spray bar system. The solenoid is activated for the amount of time indicated in the Time On box allowing the water spraybar system to wet the burlap.
Press the number 2 button to access the "edit values"
screen and enter the desired time. The solenoid is then deactivated until the paver travels the distance indicated in the Distance Off box. Press the number 3 button to access the "edit values" screen and enter the desired distance.
Paint Marker, Time On: The transverse joint location paint marker system is used to spray a paint mark on the grade next to both sides of the newly formed slab to mark the center position of the transverse joint. These paint marks can then be used to mark the saw line to create the transverse joint. The computer controls the paint marker system such that the system is activated for a desired time to create the mark. This system can be toggled on or off by depressing the number 5 button and then using the up ( ) or down ( ) arrow buttons to toggle the system on (check mark in box) or off (no check mark in box). To set how long the paint marker will spray, press the number 6 button to access the "edit values" screen and enter the desired time on. Normal time on is set between 1 and 2 seconds.
Paint Marker Offset: The offset distance is the physical distance between the paint markers and the transverse joint location (dowel spacing preset). If both paint markers are in line with the transverse joint, the offset would be set to 0.00. If the markers are not in line with the joint location, press the number 7 button to access the "edit values" display and enter the offset distance.
Note: If the joint is skewed, the paint markers must be installed to match the skew angle. The offset distance can not exceed the shortest dowel spacing.
Dowel bar spacings
079
MIDBI-059
5
6 3
2 1
DBI Spacings
Current Space 15.00
Space 1
4
Space 5
Space 4 Space 3 Space 2
Feet Feet Feet
Feet 0.00 Feet
15.00 15.00 15.00
2
MIDBI-059
The dowel bar (transverse joint) spaces must be entered into the computer for the particular job ensuring proper side bar and tie bar placement to meet job specifications. The five space distances are consecutive distances used to control the insertion of the bars. The entered distances should match the predetermined joint spacings (dowel baskets, etc.).
To change any of the spaces press the appropriate number button (1-5) to access the "edit values" screen and enter the desired distance. If a distance of zero is entered in any space setting, the corresponding space will be "grayed" out on the Run screen. If the joint spacings vary for the particular job, the current space must be entered so that the computer starts with the proper space and proceeds with the consecutive order. To change the current space press the number 6 button to access the "edit values" screen and enter the desired space number. To return to the original setting, press the ESC button. Press the OK button to store the new values.
Note: If all of the spacings are the same, the desired spacing should be entered into at least 2 space settings. The remaining spaces can be set to "0". However, it is recommended to set the spacing in each setting so that if a space needs to be changed or skipped during paving operations, it can easily be accomplished.
MIDBI-082 SBI 1
SBI 2
SBI 1 Offset
SBI 2 Offset
Paver
TBI 1
TBI 2
Offset
DBI Spacing Minimum Spacing
Bar Spacing Start
MIDBI-082
If the OK button is pressed while the Spacing screen is displayed, the bar spacing layout help screen will appear. All TBI and SBI spacings are determined from a line that is perpendicular to the edge of the slab and even with the front of the slipform mold.
If the transverse joint is at a skew, the difference between the straight line and the skewed line must be considered when setting the offset distance for the TBI(s) (see later).
Tie bar spacings
080
MIDBI-083
2 1
TBI Setup Menu TBI Enable
7
5 TBI 1 Spacings
TBI 3 Spacings Fire Adjust Enable
8 TBI 4 Spacings
MIDBI-083
TBI Enable: When tie bar inserters (TBI) are being used, it will be necessary to set the spacings. The system is designed to control up to four independent TBI’s. Press the number 1 button to select the TBI Enable setting. Using the up ( ) or down ( ) arrow buttons to enable the appropriate TBIs. Any combination of the TBIs is possible (i.e. 1; 1&2; 1,2 &3;
1,2,3&4; 1,3&4; 2 & 4; etc.). When a TBI is enabled, the corresponding Spacings box will appear. To return to the original setting, press the ESC button. Press the OK button to store the new value.
Fire Adjust Enable: The Fire Adjust Enable mode
is used to activate the insertion of bars in relation to the machine speed. If the box is not checked, the insertion will occur when commanded, irregardless of machine speed. This could cause the insertion points to vary slightly as the machine speed is increased or decreased. If the box is checked, the computer is constantly updating the insertion beginning point in relation to the paver speed. The insertion point will be more accurate. Press the number 2 button to select the Fire Adjust Enable setting. Using the up ( ) or down ( ) arrow buttons to activate or deactivate the mode.
TBI (#) Spacings: Press the corresponding number button for the desired TBI to enter the TBI (#) Setup screen (#5 for TBI 1, #6 for TBI 2, #7 for TBI 3, #8 for TBI 4).
TBI Offset
MIDBI-167
2 1
TBI 1 Setup
Type
▼ 30.00 Inches
?
5400
MIDBI-0167
TBI (#) Setup: The TBI offset distance is the physical distance between the front of the slipform mold and the center of the fork tines on the tie bar inserter, with the forks in the insertion (down) position. Enter this distance by pressing the button number 2 to access the "edit values" screen and enter the offset distance.
If the transverse joint is at a skew, measure from the side of the slipform mold to the center of each TBI. Measure over these distances in a straight line, perpindicular to the edge of the slab. Measure perpindicular from this line to a point that intersects the skewed line. This offset measurement must be added to the minimum distance setting for each TBI.
Type: The TBI type setting currently has no affect on the system.
MIDBI-053
5 3 2 1
TBI Spacings 30.00 Bar Spacing
4
Minimum Spacing Inches
5 3 2 1
4 Inches Inches Inches Inches
Inches Inches Inches Inches Inches 30.00
30.00 30.00 30.00 30.00
30.00 30.00 30.00 30.00
MIDBI -053
From the TBI (#) Setup screen, depress the
down( ) arrow to enter the TBI Spacings screen. Each TBI has five bar spacing and minimum spacing
parameters that correspond to each of the five transverse joint space parameters. This is so the spacing values for each TBI can be varied in the event that staggered transverse joint spacing is used. Use the left ( ) or right ( ) arrow buttons to select either the Bar Spacing or Minimum Spacing. Press the appropriate space button to access the "edit values"
screen and enter the correct space.
MIDBI-082 SBI 1
SBI 2
SBI 1 Offset
SBI 2 Offset
Paver
TBI 1
TBI 2
Offset
DBI Spacing Minimum Spacing
Bar Spacing Start
MIDBI-082
If the OK button is pressed while the TBI Spacing screen is displayed, the bar spacing layout help screen will appear. All TBI and SBI spacings are determined from a line that is perpendicular to the edge of the slab and even with the front of the slipform mold.
The five TBI bar spacing distances are used to control the insertion of the tie bars for the longitudinal joint.
This value is the distance between consecutive tie bars.
The five TBI minimum spacing distances are the minimum distance allowed between the center of the transverse joint and the centerline of the first/last tie bar. If the transverse joint is at a skew, the difference between a straight line, perpindicular to the edge of the slab, and the skewed line must be added to the
offset distance. To determine the bar spacings, use one of the following examples.
Example 1: If the minimum spacing between the transverse joint and the first/last tie bar, and the number of bars is known, multiply the minimum space x 2. Subtract this value from the distance between the transverse joints. Divide the remaining value by the number that is 1 less than the number of bars required, to determine the spacing between the bars.
For example, if the minimum spacing is 20 in. (50 cm), multiply by 2 for a total of 40 in. (100 cm). If the distance between the transverse joint is 144 in. (365 cm), subtract 40 in. (100 cm) for a total of 104 in. (264 cm). If 4 bars must be inserted, divide the remainder by 3 for a bar spacing of 34.6 in. (88.3 cm).
Example 2: If the number of tie bars required and the maximum spacing between bars is known, it will be necessary to determine the minimum spacing. If the transverse joints are spaced at 180 in. (457 cm), and 6 bars are inserted with 32 in. (81 cm) maximum spacing, multiply the maximum spacing x 5 (1 less than number of bars). Subtract the result from the transverse joint spacing and divide by 2 to determine the minimum spacing (180 in. - 160 in. (5 X 32)/2 = 10 in.) (457 cm - 405 cm (5 X 81)/2 = 26 cm). If the dowels in the joint are 18 in. (45 cm) in length, then the ends would be 9 in. (22.5 cm) from the center. If the first/last tie bar were inserted 10 in. (26 cm) from center, it may be too close to the ends of the dowel bars and possibly cause interference. It may be necessary to reduce the spacing between the tie bars to 30 in. (76 cm) so the minimum spacing is 15 in. (38 cm) from center.
To return to the original setting, press the ESC button.
Press the OK button to store the new values.
Note: It may be necessary to adjust the offset distance slightly during paving operations. The actual position of the first/last bar may change depending on insertion speed and machine travel speed.
173
SBI Enable
MIDBI-178
7 3 8
2 1
Side Bar Spacings
SBI 1 Offset 50.00 Inches
SBI 1 Spacing
30.00 Inches SBI 2 Offset
38.00 Inches SBI 2 Spacing
30.00 Inches
MIDBI-178
SBI Enable: When side bar inserters (SBI) are being used, it will be necessary to set the spacings. The system is designed to control two independent SBI’s.
Press the number 1 button to select the SBI Enable setting. Using the up ( ) or down ( ) arrow buttons to enable the appropriate SBIs. Any combination of the SBIs is possible (i.e. 1; 1&2; 2.). To return to the original setting, press the ESC button. Press the OK button to store the new value.
The SBI offset distance (button 2 or 3) is the
measurement from the front of the slipform mold to the center of the SBI bar holder. Press the appropriate offset button to access the "edit values" screen and enter the correct space. If the transverse joint is at a skew, determine the offset difference of the skew from side to side. This offset measurement must be subtracted from the offset distance setting for the SBI on the same side as the forward end of the skew angle.
MIDBI-179
5 3 2 1
SBI 1 Spacings 30.00 Bar Spacing
4
Minimum Spacing Inches
5 3 2 1
4 Inches Inches Inches Inches
Inches Inches Inches Inches Inches 30.00
30.00 30.00 30.00 30.00
30.00 30.00 30.00 30.00
MIDBI-0179
The SBI bar spacing distance (button 7 or 8) is used to control the insertion of the side bars in the edge of the slab. This value is the distance between consecutive side bars.
The five SBI minimum spacing distances are the minimum distance allowed between the center of the transverse joint and the centerline of the first/last side bar. To determine the bar spacings, use one of the following examples.
Example 1: If the minimum spacing between the transverse joint and the first/last side bar, and the number of bars is known, multiply the minimum space x 2. Subtract this value from the distance between the transverse joints. Divide the remaining value by the number that is 1 less than the number of bars required, to determine the spacing between the bars.
For example, if the minimum spacing is 20 in. (50 cm), multiply by 2 for a total of 40 in. (100 cm). If the distance between the transverse joints is 144 in. (365 cm), subtract 40 in. (100 cm) for a total of 104 in. (264 cm). If 4 bars must be inserted, divide the remainder by 3 for a bar spacing of 34.6 in. (88.3 cm).
Example 2: If the number of side bars required and the maximum spacing between bars is known, it will be necessary to determine the minimum spacing. If the transverse joints are spaced at 180 in. (457 cm), and 6 bars are inserted with 32 in. (81 cm) maximum spacing, multiply the maximum spacing x 5 (1 less than number of bars). Subtract the result from the transverse joint spacing and divide by 2 to determine the minimum spacing (180 in. - 160 in. (5 X 32)/2 = 10 in.) (457 cm - 405 cm (5 X 81)/2 = 26 cm). If the dowels in the joint are 18 in. (45 cm) in length, then the ends would be 9 in. (22.5 cm) from the center. If the first/last side bar were inserted 10 in. (26 cm) from center, it may be too close to the ends of the dowel bars and possibly cause interference. It may be necessary to reduce the spacing between the side bars to 30 in. (76 cm) so the minimum spacing is 15 in.
(38 cm) from center.
To return to the original setting, press the ESC button.
Press the OK button to store the new values.
Note: It may be necessary to adjust the offset distance slightly during paving operations. The actual position of the first/last bar may change depending on insertion speed and machine travel speed.
Distance setup
082
Encoder Enable
MIDBI-173
5 6 4
3 1
Distance Setup
Calibration Factor
Clear Totals1.025 7
101.25 Calibration
Stop
Distance Traveled
ft 3 3 3
Start 2
1.010 8
3 3 3 4 5 4 4 5 4
Success
MIDBI-173
Encoder Enable: The encoder enable sets the number of encoders, or pulse pickups, used to measure the distance traveled and where they are connected. A single encoder, or pulse pickup, can be connected to any of the SBI control boxes (1 or 2), any of the TBI control boxes (1, 2, 3 or 4) or to the display control box. Press the number 1 button to select the first Encoder Enable setting (normally the left side). Press the number 2 button to select the second Encoder Enable setting (normally the right side). Using the up ( ) or down ( ) arrow buttons to scroll through the various choices and select the icon the corresponds to where the encoder is connected.
Normally the icon without the arrows is selected. If the encoder, or pulse pickup, is running backwards, select the icon with the double arrows. To determine if the encoder, or pulse pickup, is running backwards, access the Distance display screen from the Test menu. Move the machine forward and observe the encoder count for the appropriate encoder. The count should be increasing. If the count is decreasing, the encoder, or pulse pickup, is running backwards.
Select the icon with the double arrows. A single encoder, or pulse pickup, is normally used if paving a single lane. Two encoders, or pulse pickups, are used when pouring 2 or more lanes, to give a true centerline measurement.
Calibration Factor: The calibration factor is set by the computer after the encoders have been calibrated.
If a single encoder is used, the calibration factor for the corresponding encoder will be displayed. If two encoders are used, the calibration factor for both encoders will be displayed. Each encoder can be calibrated seperately. The factors are normally very near 1.000. If only one encoder is being used, the calibration factor for the unused side has no affect on
the system. If the travel distance is off slightly during pouring operations, the calibration factor for either, or both, encoders can be tweaked. Press the number 3 button to access the "edit values" display for the left encoder and button 4 for the right encoder and adjust the factor. If the paver has traveled an actual distance which is more than the displayed distance on the Run screen, increase the value slightly (normally no more than 0.001 at a time) and recheck. If the actual distance is less than the displayed distance, decrease the value slightly (normally no more that 0.001 at a time) and recheck.
Clear Totals: The clear totals button is used to clear the distance traveled on the Run display and to clear the number of "fire" and "implant" signals on screen #7 of the Input/Output display of the Test menu. To clear the totals, restart the controller. Access the Setup menu (# 3) without accessing any other menu. From the Setup menu, access the Distance Setup menu (#
6). Press the #8 button. When the totals are cleared, the display will indicate "Successful". If the totals fail to clear for some reason, the display will indicate
"Failed". It will be necessay to restart the controller to attempt to clear the totals again.
Note: If the Run screen is accessed before attempting to clear the totals, the #8 button will be
"grayed" out and not accessable.
Calibration: Encoder calibration is necessary due to the manufacturing tolerances of the track encoder wheels and the wear on the track encoder wheels as well as other factors that may have an affect on the feedback from the encoder mounted on the track encoder wheel. Pulse pickup calibration is necessary due to manufacturing tolerances of the track drive motor. To calibrate the track encoders or pulse pickups, power the computer on with the paver sitting still at a reference point. Once the computer has been powered on, press the number 5 button to Start the calibration process and track the machine a determined distance. The further the distance traveled by the paver the more accurate that the calibration factor will be (recommended at least 100 ft. (30 m)).
After the paver has traveled the predetermined distance, stop the paver and press button number 6 to stop the calibration process. Press the number 7 button to access the "edit values" display and enter the exact distance traveled. After the correct distance is entered, the computer will generate the calibration factors.
