Bosch Rexroth CS660 Use and care manual

CS660/CS661 Spreader
Controller
Calibration Manual

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Table of Contents
Bosch Rexroth Canada Corp. reserves the right to revise this information at any time and for any reason and reserves the
right to make changes at any time, without notice or obligation, to any of the information contained in this piece of
literature. The information shown in this manual features the latest version of software as of publication; therefore, some
features shown will not exist on older versions of software in use by some customers.
Please check for updates at: www.boschrexroth.ca/cs
1
Setup Screen Layout
3
2
Set up for Basic Operation
4
2.1
System Configuration
4
2.2
Inputs and Outputs Configuration
7
2.3
Ground Speed Calibration
9
2.4
Valve & Sensors Set up
9
2.5
Material Setup and Calibration
11
2.5.1
Solid Material Setup
11
2.5.2
Solid Material Calibration –Manual or Readback Gate
11
2.5.3
Solid Material Calibration –Auto Gate
12
2.5.4
Prewet and Anti-icing Material Setup
15
2.5.5
Prewet and Anti-icing Material Calibration
15
2.6
Material Catch Test
16
3
Set up for additional feature functions
17
3.1
Conveyor Forward and Reverse
17
3.2
Spinner Forward and Reverse
17
3.3
Spinner & Conveyor Forward and Reverse
17
3.4
3Boom Anti-ice (DLA)
18
3.5
Dual Spinner
18
3.6
Air Gate
19
3.7
Gate Readback and Automatic Gate
19
3.8
Lane Control
20
3.9
(4 knob) Spreader+1Boom Anti-ice
20
3.10
(4 knob) Spreader+3Boom Anti-ice
21
3.11
(4 knob) Spreader+Cross Conveyor
21
3.12
(4 knob) Spreader+3Boom Anti-ice + Cross Conveyor
21
4
Set up Profiles
22
5
Set up Joystick Operation
23
6
Set up Error Messages
25
7
Load, Retrieval Parameter and Clear historic error messages
27
8
Appendix –CS-660 System layout, Cable Drawings

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1Setup Screen Layout
Three steps to set up the system:
System –Truck Info, operation options, operator access level, temp sensor, error severity
Sensors & Valves –Configure all sensors, and valve settings
Materials –Set up, and calibrate all solid and liquid materials
Joystick –If joystick function is enabled set up and calibrate all modes and axis

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2Set up for Basic Operation
To enter Programming mode from the operator screen, press the program mode icon with the
USB Program key inserted.
2.1 System Configuration
1. Set the units to imperial (LBS/Mile) or metric (Kg/Km).
2. Set the TRUCK ID.
3. Set the REGION NAME.
4. Set the DRIVER ID (optional), 4 driver IDs allowed.
Note: Configuring driver ID to ‘USER” enables operators to enter user defined driver ID on operator screen.
5. Set the type of Temperature Sensor (optional).
6. Set the Options –see Option Checkboxes in this manual
7. Set the items that the user has access to (optional).
8. Set Blast Timer, 0-timer disabled (optional). This should be set less than Err01 delay.
9. Set Percentage of Temp. compensation when there is a 3 degree change (optional).
10. Set the vehicle speed alarm (optional).
11. Select auxiliary options (check marks)
Press here to enter program
mode. If Icon is not colored,
the PGM key is not inserted
or it is the wrong key.
Main Page
Secondary Page
Joystick Page
Speed Calibration
Conveyor Valve
Spinner Valve
Gate Valve
Prewet Valve
Anti-Ice Valve
Solid Material Calibration
Prewet Material Calibration
Anti-Ice Material Calibration
Swipe up/dn to see more
checkboxes
Swipe up/dn to see
more checkboxes

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Choose
function
Valve coil
PWM
dither
Save
settings
Blast by distance –Operator can enter a distance for blasting (Future option)
Momentary blast –Operator must hold blast button down
Boot to pause –Automatically pause the system on boot
Prewet/liquid interlock - Prewet and Anti-icing operation interlock with an asymmetrical valve
IOT tracking –Enable AVL interface (default is GPS)
4 Knob Console –Enable external 4 knob console
Eq Rates –Define only start and end rate as well as increment
CRS blast on –Turn on cross conveyor blast
Save last knob –Remember the knob positions when powering off then on again
Voice disabled –Turn off voice feedback
Volume adjust –Allow operator to adjust volume
Summer Mode –Enable summer mode
Default Joy Screen –Always show joystick screen
Enable Profiles –Enable the use of profiles
Allow sim deice –Allow prewet to operate separately from conveyor to provide anti icing
Under app solid off –Turn off solid under application warnings
Under app prewet off –Turn off prewet under application warnings
Under app deice off –Turn off deice under application warnings
12. Press the secondary options icon to access additional setup parameters. All additional IOs can be
set up by using the drop down menus in the I/O mapping section. The drop down fields on the left let
you pick an input or output (digital or analog), and the drop down directly to the right is the function of
that particular I/O port. For example, you can select “Analog In 2” on the left, and on the right you can
select “Temperature” to assign that controller input to be connected to a temperature sensor. Refer to
the Special Features with IO mapping section.
Note: the RC controller wiring must match what is chosen here.
GPS
Cable
Operator
screen
IoT
Cable
Operator
screen

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WiFi/Keyboard/Network/Screen calibration/Date&Time
Set WIFI/Network/Screen Calibration/Date&Time (if required).
Note: “Save settings” only applies to these items (WiFi, Screen Calibration, Time).
13. Click on WiFi network icon to set up WIFI connection
The WiFi setup is almost identical to standard Windows.
-Uncheck ‘Notify me …’ to stop this window from popping up every time the system starts up.
-Click ‘Connect’ and enter Network key
Click on LAN & IP address icon to configure LAN and assign an IP address
LAN & IP
Address
WiFi
Network
keyboard
show/hide
NOT USED WiFi Setup NOT USED

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Note: Only one preferred network can be stored at a time, or this will cause a conflict!
If a preferred network already exists, please ensure you have firmware version 6 or higher installed and
do the following:
Close the Wifi setup dialogs shown on the right so you are back to the setup screen.
Press and hold the WiFi network icon for 5 seconds to clear any preferred networks.
Now you can perform the WiFi setup.
Note: Any changes to WiFi/ Network settings/ Time/Screen recalibration need to be saved by clicking the
save icon on the bottom of the screen.
2.2Input and Output Configuration
To configure appropriate inputs or outputs press the additional options icon to set up I/O Mapping.
Note: the RC controller wiring must match what is chosen here.

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Configurable IO Options
Digital Inputs (DigIn1-8,CANIO DigIn1-8)
Material Detect
Material Change (13 or 24)
Boom Left
Boom Center
Boom Right
Dual Spinner (double rate)
Spinner Reverse
Conveyor Reverse
Spreader Off (spn+conv+prewet)
DLA Off
CRS (cross conveyor on/off)
Re-circulation
Flush
Body Up
Plow Down
Wing Down
Gate In
Low Oil
Pause
Blast
Liquid Lvl
L-R
Dump Limit
Air Gate
PTO Enable
Vehicle Reverse
Re-Activate 1
Re-Activate 2
…
Digital Inputs (Aux DigIn1-8)
L1 –4 (Light Outputs, 2.2A)
L5 –8 (Light Outputs, 3.5A)
Digital Out
GS12 –When there is ground speed
Pause –When spreading paused
ConveyorRvs –When Reverse Button being pushed
Boom Left
Boom Center
Boom Right
Analog In
Temperature
Pressure
Low Oil
Op 1 (Future feature)

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Pulses/rev
in Auto
mode
Control mode
An extra
“push” to
overcome the
friction of a
heavy load on
the conveyor
when starting
from 0 speed
2.3Ground Speed Calibration
1. Select speed icon to enter into the ground speed calibration screen.
2. Choose which calibration option best suits your situation. Automatic or manual.
Note: Highly recommended to use the typical vehicle speed during spreading. And a more accurate real
time GPS speed is preferred for more precise speed calibration.
2.4 Valve & Sensor Setup
1. Tap the icon for the function you with to null.
2. Select the control mode:
Spinner –Manual (default), Half Lane, One Lane
Conveyor/Auger –Auto (default), Open LP, Man-Spd, Manual
Prewet –Off, Fixed, V-Flow (default), Manual, Manual-SPD, Return Oil, Open Loop
Anti-Icing (Anti-icing) –Off (default), 1 Boom, 3 Boom, Manual %
3. Set correct conveyor sensor pulses/rev if Auto is selected.
4. Ensure the hopper is empty, and the truck is safe to operate.
5. Start the engine to achieve adequate oil flow.
Note: If the Auto mode is selected it is strongly recommended to run Auto Null.
Follow instructions for speed calibration
Enter number manually

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Adjust
min/max
output
Auto Nulling
1. Press “Start” to begin. This procedure will automatically ramp up the conveyor motor speed and then
ramp down to capture the both “Min” and “Max” speed values and storing them as a saved calibration.
Note: This feature can only be used with motors with speed sensor. It takes about 30~60s to complete.
2. Calibrated values will be shown in the Min output & Max output text boxes
3. Please check the “Min” null value to verify it is minimum. (< 5RPM). Do this by pressing on the Min
output value (conveyor will start to turn). Press again to stop.
Manual Nulling
1. Press “Min” value field to pop up the UP/DN arrows and enter into edit mode.
2. Use up and down arrows to adjust speed so that the motor just begins to turn
3. Press the “Min” value field again to end the edit mode and accept the value
4. Do the same for “Max” to adjust the motor to a safe max speed or until the RRM readout stops to
increase.
5. Forward Gain and Blast settings can also be adjusted

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STEP 1
Ensure system safe to run
Manual Gate:
Manually adjust gate &
enter the gate position
Readback Gate:
Manually adjust gate (no
need to enter)
Continue to next step
Stop to abort
Material Names:
Select name from list
Click to popup keypad
Enter to save
Solid Rates:
Setpoints for 9 conveyor
knob positions
Unit of Solid Rate:
Kg/km or Lb/mi
Cal Gate:
Gate position used for
material calibration
2.5Material Setup & Calibration
2.5.1 Solid Material Setup
Tap on the solid material icon to configure materials desired. It allows to set up to 4 different
solid materials, and 9 application rates and a blast rate for each material.
2.5.2 Solid Material Calibration –Manual or Readback Gate
1. Prepare a container to catch material discharged
2. Make sure that sufficient material in the hopper and the system is safe to run.
3. Press ‘START’ to proceed and follow the instruction on the screen
Note: Press “STOP” button to stop the process anytime during calibration.

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STEP 2
Dial to 2nd or 3rd position for
decent conveyor speed
Continue to next step
Stop to abort
Complete!
When the material
calibration ends the
Wt/Rev at the calibrated
gate position is
refreshed.
STEP 3:
Recommend to discharge
minimum 100kg or 220lbs
material (more for better
resolution)
Enter weight of the
material collected
Continue to next step
Stop to abort
2.5.3 Solid Material Calibration –Auto Gate
1. Prepare a container to catch material discharged
2. Make sure that sufficient material in the hopper and the system is safe to run.
3. Press ‘START’ to proceed and follow the instruction on the screen
**Auto Gate operation has two calibration points, Wt/Rev at Gate position 1 and 3. Simply follow steps
on screen to go through the calibration process.

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STEP 1:
Ensure system safe to run
Make sure the Conveyor
and Gate cylinder has
been correctly set up and
calibrated
Start to proceed
STEP 2:
Continue if you have
a container ready and
sufficient material
always above the gate
opening throughout
the calibration process
Continue to next step
Stop to abort
STEP 3:
Controller
automatically move
the gate to position 1
Continue to next step
Stop to abort
STEP 4:
Recommend to discharge
minimum 100kg or 220lbs
material (more for better
resolution)
Enter weight of the
material collected
Continue to next step
Stop to abort

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STEP 5:
Controller
automatically move
the gate to position 3
Continue to next step
Stop to abort
STEP 6:
Recommend to
discharge minimum
100kg or 220lbs
material (more for
better resolution)
Enter weight of the
material collected
Continue to next step
Stop to abort
Complete!
When the material
calibration ends both
Wt/Revs at calibrated
gate position 1 and 3
are refreshed.

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Material Names:
Select name from list
Click to popup keypad
Enter to save
Unit of Prewet Rate:
Liter/Ton
Gallon/Ton
Unit of Anti-ice Rate:
Liter/Lane.Km
Gallon/Lane.mi
STEP 2
Dial to 2nd or 3rd
position for
decent flow
STEP 1
Ensure system safe to run
Continue if you have a
container ready and
sufficient liquid
throughout the calibration
process
2.5.4 Prewet and Anti-icing Material Setup
Tap on the prewet material icon or anti-ice material icon to configure materials desired. It
supports 4 prewet and 4 anti-ice materials, and 9 application rates and a blast rate for each material.
2.5.5 Prewet and Anti-icing Material Calibration
1. Prepare a container to catch liquid discharged
2. Make sure sufficient liquid in the tank and the system is safe to run
3. Press ‘START’ to proceed, and follow the instruction on the screen

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STEP 3
Discharge more
liquid for better
calibration accuracy
STEP 1
Enter desired rate speed
Duration
Press ‘Continue’
STEP 2
Measure material
Enter the value
Press ‘Continue’
2.6Material Catch Test
2.6.1 Solid Material Catch Test
1. Tap on solid, prewet or anti-icing icon to enter into the material calibration screen.
2. Place an adequate catch container under the spreader discharge chute.
3. A wt/rev (kg/rev or lb/rev) will be calculated and displayed on the bottom right of the screen.
4. Repeat this procedure for all solid materials (use the left and right arrows to select material types).

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‘R’ –Forward, ‘R’ - Reverse
‘R’ –Forward, ‘R’ - Reverse
A digIn (Junction Box or CANIO board)
A digIn (Junction Box or CANIO board)
2.6.2 Liquid Material Catch Test
These same procedures apply to pre-wet and liquid. The unit of calibrated value is pulses/liter or
pulses/gallon.
3Set up for Additional Feature Functions
3.1 Conveyor Reverse
This feature supports bi-directional conveyor operation. It requires a digital input to toggle the
direction of the conveyor motor. Once an input is configured for ‘ConveyorReverse’ the following
proportional outputs are automatically mapped:
Junction Box V1-B Conveyor Forward
Junction Box V1-A Conveyor Reverse
Note: When setting up conveyor valve only forward output needs to be trimmed since both Conveyor forward
and Reverse outputs share the same Min & Max null values.
3.2Spinner Reverse
This feature supports bi-directional spinner operation. It requires a digital input to toggle the direction
of the spinner motor. Once an input is configured for ‘SpinnerReverse’ the following proportional outputs
are automatically mapped:
Junction Box V2-B Spinner Forward
Junction Box V2-A Spinner Reverse
3.3 Conveyor & Spinner Reverse
This feature supports bi-directional spinner operation. It requires two digital inputs to toggle the
direction of the spinner and conveyor motors. Once an input is configured for ‘SpinnerReverse’ the following
proportional outputs are automatically mapped:

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‘R’ –Forward, ‘R’ - Reverse
2 digIn (Junction Box or CANIO board)
All booms must be open for nulling
Button color is RED when boom is open
Junction Box V1-B Conveyor Forward
Junction Box V1-A Conveyor Reverse
Junction Box V2-B Spinner Forward
Junction Box V2-A Spinner Reverse
3.43Boom Anti-ice (DLA)
This configuration is a dedicated 3 Boom Anti-ice system. It requires 3 digital inputs (junction box or
CANIO board) and 3 digital outputs for boom control.
To configure valve outputs it is highly recommended to use AUTONULL.
3.5Dual Spinner
This feature supports a single or dual spinner operation. It requires a digital input to switch on/off dual
spinner function.

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‘D’ –Single Spn, ‘D’ –Dual Spn
Toggle 1st  3rd materials & calibrated gates
A digIn (Junction Box or CANIO board)
A digIn (Junction Box or CANIO board)
3.6Air Gate
This feature supports air gate operation. It requires a digital input to monitor the air cylinder position.
When the input status changes the controller switch between 1st and 3rd solid and prewet materials, and
also set operation gate position to calibrated gate position for the material selected.
3.7Gate Readback and Automatic Gate
Gate Readback Automatic Gate
It requires a gate sensor to measure It requires a gate cylinder with a
the current gate position. sensor to measure the gate position.
Sensor A2-A (Junction box) Sensor A2-A (Junction box)

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3.8Lane Control
The conveyor and spinner motor sizes and flow rates should be chosen as to limit the number of lanes
the system can actually cover before lane calibration takes place.
1. Tap on the “spinner” icon to enter into spinner menu, and select “Half Lane” or “One Lane”
2. Press “Start” Button.
3. Spinner will begin to output, and arrows will appear to allow you to increase/decrease the speed.
You may also turn the center knob to activate the conveyor.
4. Use the arrows to set the desired speed to spread material to half lane or one lane width.
5. Press “Stop” to end the calibration and save calibration value.
3.9 (4 knob) Spreader + 1Boom Anti-ice
This configuration utilizes a 4 knob console, and control a spreader (spinner, conveyor, prewet) and a
1boom anti-ice simultaneously.
Steps to set up
-Move gate to max opening
-Press Max value to highlight
-Record sensor position
-Set max gate height
-Press Max value again to save
-Move gate to min opening
-Press Min value to highlight
-Record sensor position
-Set min gate height
-Press Min value gain to save
Steps to set up
-Up/Dn to move gate to max
-Move gate to max opening
-Press Max value to highlight
-Record sensor position
-Set max gate height
-Press Max value again to save
-Up/Dn to move gate to min
-Move gate to min opening
-Press Min value to highlight
-Record sensor position
-Set min gate height
-Press Min value gain to save